hp tooling 2024-#4

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2024 – 4 

ARGUS 

A wholistic approach to gear grinding 

Reishauer 216x207,5mm digitale Welt Titelseite.indd 1 07.10.2024 13:01:31 

■ PCD milling program for aluminum machining ■ Looking back: LACH DIAMOND INC. is founded ■ 

■ A new level of flexibility in gear grinding ■ Roadmap for the decarbonization of grinding processes ■

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editorial 

Eric Schäfer 

editor-in-chief 

It won’t get any better than this… 

…is easy to say. But most of the time it could get a little better. 

It doesn’t always have to be the big hit. It’s often the little 

things that allow the optimization potential of a tool to be 

exploited to the full. 

This was clearly demonstrated at the recent trade fairs by 

numerous new and improved tool developments, in which 

designers have managed to squeeze even more performance 

out of a tool, not least through small but effective details. For 

example, better chip control thanks to optimized cutting 

edge geometry, which is only possible with laser processing. 

This and other examples can be found in this issue. 

How even a modified tool can contribute to the sustainability 

of its manufacture is shown in our technical article 

“Development and grinding investigation of a ceramic bond 

formulation for low-temperature firing”, which is 

well worth reading. 

Increasingly complex requirements are also being placed on 

machine tools and components such as clamping devices, 

control software and drives in order to ensure precision, 

efficiency and process reliability. In this issue, we also show 

how ball screws and linear guides, for example, contribute 

to this, and provide an up-to-date overview of the latest 

developments in the field of precision machining. 

It could hardly be better. 

Eric Schäfer 


Ø0.5 

6 flutes 

Deburring & Chamfering 

Ultra high speed & feed rate 

Excellent positioning accuracy 

Ø32 

Wide range, no limits 

for your variety needs 

NC Deburring 

60° / 90° 

MCC Mill 

60° / 90° Deburring & 

55° / 60° Threading 

Front and back Chamfer Mill 45° 

JIMMORE 

International Corp. 

E-mail: trade@jimmore.com.tw 

https://nine9.jic-tools.com.tw

table of contents 

cover story 

Tooling, a key part of the overall generating gear grinding process 

written by Walter Graf 6 

materials & tools 

Manufactured from 99 % reprocessed carbide 10 

Innovative tools 11 

PCD milling program for aluminum machining 12 

Better chip control with laser geometries 14 

Six times higher metal removal rate 15 

The future is here 17 

Three new “crazy” high-performance cutting tools 18 

processes 

A new level of flexibility in gear grinding 26 

Centerless grinding rethought 28 

Roadmap for the decarbonization of grinding processes 30 

High-performance micro-milling of high-hardness steels: e.g. for bipolar plates 34 

machining center 

Planetary Lapping machine for PCD and CVD 37 

Together to success 38 

Successful conversion of production 40 

England receives its first arc80X 41 

New standards with world premieres 43 

A new ball pin leaves the machine every seven seconds 45 

components 

Modular systems for cable carrier systems 46 

Mobile robots reduce costs for SMEs 47 

New AI solution launched to accelerate the CNC machining estimating process 48 

Precise, highly reliable linear technology solutions for machine tools 49 

Fast on the move 50 

news & facts 20 

fairs 5 

impressum & company finder 53 

4 no. 4, November 2024

fairs in alphabetical order 

bauma Shanghai, China 

(November 26-29, 2024) 

CIMT Beijing, China 

(April 21-26, 2025) 

CMTS Toronto, Canada 

(Sept 29-Oct 2, 2025) 

EMO Hanover, Germany 

(September 22-26, 2025) 

current status 

2024 

2025 

2025 

2025 

FEIMEC Sao Paulo, Brazil 

(May 5-9, 2026) 

GrindTec Leipzig, Germany 

(March 11-14, 2025) 

Hannover fair Hanover, Germany 

(March 31 - April 4, 2025) 

2025 

2025 

2026 

HI Tech & Industry Herning, 

Scandinavia (Sept 30-Oct 2, 2025) 

Denmark 

2025 

LIGNA Hanover, Germany 

(May 26-29, 2025) 

MACH-TECH and Budapest, Hungary 

INDUSTRY DAYS (May 2025) 

METALEX Bangkok, Thailand 


MOULDING Stuttgart, Germany 

EXPO (May 6-9, 2025) 

2025 

2025 


2025 

NORTEC Hamburg, Germany 

(=METAV) (February 3-5, 2026) 

2026 

PARTS FINISHING Karlsruhe, 

DeburringEXPO (November 11-14, 2025) 

Germany 

2025 

SIAMS Moutier, Switzerland 

(April 21-24, 2026) 

SIMTOS Seoul, South Korea 

(April, 2026) 

2026 

2026 

sps Nuremberg, Germany 


STEELFAB Sharjah, United Arab 

(January 13-16, 2025) Emirates 

TIMTOS Taipei, Taiwan 

(March 3-8, 2025) 


2025 

2025 

TMTS Taichung, Taiwan 

(March, 2026) 

2026 

trade fair dates as by middle of October 2024; we are not responsible for reliability of these dates 

no. 4, November 2024 

5

cover story 

Tooling, a key part of the 

overall generating gear grinding process 

written by Walter Graf 

Shopfloor environment with ARGUS monitoring of process and tooling 

In the precision-driven field of 

gear manufacturing, the efficiency 

and reliability of gear grinding 

machines are crucial. This 

article examines the characteristics 

of Reishauer gear 

grinding machines and 

their integrated system approach. 

While all system 

components are important, 

this article focuses on the 

tooling, with other elements 

addressed in less detail. 

The Reishauer 

Circle of Competence 

At the core of Reishauer’s grinding 

philosophy lies the “Circle of Competence”, 

a holistic system encompassing 

every aspect of the gear grinding 

process. Instead of concentrating 

solely on building machine tools, 

Circle of Competence 

Reishauer offers an integrated system that 

includes machines, automation systems, 

tooling, technol ogy, digital solutions, 

and support services. This comprehensive 

approach ensures 

that all elements function 

together effectively, enhancing 

efficiency and precision in gear 

grinding. 

Machines: 

precision and reliability 

Reishauer gear grinding 

machines are engineered for 

precision, reliability, and high 

performance. Equipped with advanced 

CNC controls and modern 

interface concepts, they maintain 

consistent quality and machine availability. 

This consistency is crucial for 

manufacturers requiring high-volume 

production with repeatable accuracy. 


cover story 

Automation: integrated efficiency 

The company builds automation systems that 

integrate with the gear grinding machines 

to meet modern production demands. These 

modular and customizable systems allow 

manufacturers to tailor automation to their 

specific needs. By synchronizing automation 

with machine operations, idle times are minimized, 

and throughput is maximized. 

Digital systems: 

industry 4.0 integration 

Furthermore, Reishauer provides digital 

solutions that are aligned with Industry 4.0 

standards. The digital portfolio includes: 

predictive maintenance: uses data 

analytics to anticipate maintenance needs, 

aiming to reduce downtime 

advanced analytics: offers insights into 

machine and tooling performance and 

process optimization 

process monitoring: tracks key 

parameters throughout the grinding 

operation to ensure consistent quality 

Integrating these digital systems enhances the 

performance and output of the machines and 

the tooling, enabling manufacturers to improve 

efficiency and productivity. 

Tooling: an integral component 

supported by digital technology 

A key feature of Reishauer’s system is the inhouse 

production of tooling components such 

as grinding wheels, diamond dressing tools, 

3D-printed coolant nozzles, and clamping 

fixtures. By manufacturing these tools internally 

and using a digital process monitoring 

system, the company ensures they are precisely 

matched to their machines and grinding 

processes. This synergy between tooling and 

machinery enhances performance, consistency 

and reliability, highlighting that tooling 

is not merely an accessory but an essential 

part of the entire system. 

figure 1 – Grinding wheel monitoring 

whereas the finishing strokes display an increasing intensity in the same direction. 

The decrease in grinding intensities during roughing indicates process-induced 

wear of the threaded grinding wheel. Ideally, a calibrated force 

model would maintain almost constant grinding intensities across the full 

grinding wheel width. The observed drop in intensity during roughing is 

attributed to continuous microscopic deterioration of the bond-grain matrix 

of the threaded wheel, leading to gradually reduced material removal from 

the workpieces. The increase in grinding intensity during finishing strokes 

compensates for the reduced material removal from the preceding roughing 

strokes. This wear effect on the threaded wheel results in an unstable process 

and causes rejected workpieces, depicted as dark red dots on the lower left 

side of the roughing stroke point cloud. In this case, the user had to change 

the grinding wheel specification to stabilize the process. 

Evaluation of the performance of clamping devices 

As with the grinding wheels, the ARGUS can also assess the effectiveness of 

the clamping tools. Monitoring the grinding intensity, for example, provides 

information on concentricity deviations that indicate faulty clamping devices 

or deviations in pre-machined workpieces. In the example shown in figure 2, 

roundness differences between the two workpiece spindles, C1 and C2, can 

be seen. ARGUS uses complex algorithms to simplify the interpretation of 

the dynamic effects on grinding intensity and to enable process analysis 

without requiring the user to have specific expertise. In this case the C2 

spindle was misaligned, increasing intensities due to out-of-roundness. After 

aligning the workpiece spindle C2 on reaching 4,000 workpieces, both spindles 

showed an identical range of grinding intensities, as shown in figure 2 

on the right side of the diagram. 

Reishauer employs the ARGUS process 

monitoring system to evaluate and continuously 

improve tooling. This system leverages 

data and analytics to optimize tooling processes, 

improving production efficiency. 

Evaluation of grinding worm behavior 

By highlighting the synergy between ARGUS 

and tooling, figure 1 illustrates the grinding 

intensities across the shifting axis covering 

the full width of a grinding worm for producing 

over 5,000 workpieces. The upper blue 

point cloud represents roughing strokes, while 

the lower green point cloud represents finishing 

strokes. The roughing strokes show a decreasing 

grinding intensity from right to left, 

figure 2 – Monitoring clamping devices 


7

cover story 

Advantages of large database model 

Evaluation of the performance of 

diamond dressing rolls 

Diamond dressing tools are also monitored within the process. 

Measured dressing intensities objectively evaluate a 

dresser’s useful service life, often exceeding the indicated or 

guaranteed dressing cycles. To be on the safe side users traditionally 

perform eight roughing strokes and two finishing 

strokes during dressing. With ARGUS dressing monitoring, 

the number of dressing strokes can be reduced, as the monitoring 

system indicates after how many strokes the grinding 

worm is properly dressed. 

As of September 2024, Reishauer had accumulated around 

30 million grinding cycles and all associated data points, 

each cycle comprising approximately one million data points, 

stored anonymously in a dedicated cloud. This substantial 

data pool allows for applying data science and AI for pattern 

recognition and algorithm optimization. Insights gained 

from data analysis are continually incorporated into updates 

for the benefit of all subscribers. In terms of tooling the data 

analysis leads to an objective evaluation of the performance 

of tools, whether being grinding wheels, diamond dressers, 

or clamping fixtures. These valuable insights are used to 

improve tool performance continuously. 

ARGUS minimizes tooling costs by providing detailed 

insights into the condition of the tools. This insight allows 

using tools to their performance limits without prematurely 

removing them from the production process based on the 

potentially incorrect assumption that their service life is nearly 

exhausted after a predefined number of usage cycles. 

Technology: addressing modern challenges 

The advent of electric drives (e-drives) has introduced new 

challenges in gear manufacturing, including higher rotational 

speeds, increased torque, and stringent requirements to minimize 

noise, vibration and harshness (NVH). Reishauer addresses 

these challenges with advanced technologies such as, 

for example: 

twist-control grinding: manages the distribution 

of twist along the gear flank to meet 

specific performance criteria 

polish grinding: enhances surface finish to improve 

gear performance and longevity; moreover, polish 

grinding reduces gear noise (NVH) in transmission, 

which is particularly important in electric drives 

These technological innovations enable manufacturers to 

produce gears that meet the demanding specifications of 

modern applications. 

Services: ensuring maximum availability 

A global network of service engineers and decentralized spare 

parts stores ensures that Reishauer machines maintain maximum 

availability. Their support services minimize downtime 

and provide customers with prompt assistance, contributing 

to the reliability of the entire system. 

Proven performance and global adoption 

With over 1,000 modern RZx60 machines operating worldwide 

around the clock, Reishauer’s gear grinding machines 

have demonstrated reliability and effectiveness on a global 

scale. Leading automotive manufacturers and suppliers rely 

on these machines to produce gear sets that meet the most 

demanding standards. 

Conclusion 

Reishauer’s gear grinding machines stand out due to their 

integrated system approach, where each element – from 

tooling to digital systems – is designed to support the others. 

This philosophy ensures high precision, reliability, and efficiency, 

meeting the evolving demands of gear manufacturing. 

By recognizing tooling as an essential part of a cohesive 

system, the company exemplifies how integration and innovation 

drive performance in engineering. 

further information: www.reishauer.com 



Superior life 

and grinding speed 

cool tools 2024 

MICRO DRILLS FOR TITANIUM 

Diameter range 

Drilling depth 

Machinable materials 

Ø 0.2 - 2.0 mm 

3 x d and 6 x d 

All titanium grades 

CHATTER-FREE END-MILLS 


Effective length 

Flutes 


Ø 1.0 - 8.0 mm 


Z4 and Z5 

P M K N 

S1 S2 S3 

SUPER FINISHING END-MILLS 

Cool SF 

Weiler Abrasives, a leading provider of abrasives and 

power brushes for surface conditioning, has announced its new 

Metalynx MAX Ceramic flap discs. The flap discs feature enhanced 

abrasive cloth and improved flap configuration to provide users 

with longer product life and greater efficiency, removing up to 40 % 

more material. 

“The new Metalynx MAX Ceramic flap discs are engineered to deliver 

superior life and grinding speed”, says Uroš Filipič, product manager, 

Weiler Abrasives. “This allows users to remove more metal in less time, so 

they can get more done.” 

Metalynx MAX Ceramic flap discs feature advanced ceramic alumina 

grains that maintain a high cut rate. The flap configuration has been improved 

to optimize the exposure of new abrasive cloth, maximizing 

the disc’s effectiveness. The innovative design increases disc life and enhances 

performance, removing more material and reducing change-overs. 

In addition Metalynx MAX Ceramic flap discs have a topcoat that grinds 

cool, protecting high-value parts from heat discoloration. The flap discs 

contain less than 0.1 % of iron, sulfur and chlorine, for contaminant-free 

grinding of stainless steel and other high-value metal parts. 

Metalynx MAX Ceramic flap discs are available in standard F27 and F29 

styles as well as a unique angled shape. Metalynx MAX Ceramic angled 

flap discs are designed for grinding fillet welds, T-joints and other hardto-reach 

areas. The 90-degree angled flap design optimizes flap-to-metal 

contact for improved user control and feel while grinding. 

further information: www.weilerabrasives.com 


Effective length 

Flutes 


Ø 1.0 - 8.0 mm 


Z5 and Z6 

P 

M K N 

S1 S2 S3 

MIKRON SWITZERLAND AG 

Division Tool 

6982 Agno | Switzerland 

mto@mikron.com 

www.mikrontool.com


Manufactured from 99 % reprocessed carbide 

A milling cutter which is extremely powerful, universally 

applicable and at the same time manufactured 

in a resource-efficient manner: sounds unlikely? With 

the ProACT-Mill UNI and ProACT-Mill UNImax 

from CERATIZIT, a tool series is now available that 

easily meets every requirement. 

It’s all thanks to the latest geometry and coating technologies 

combined with the carbide grade CT-GS20Y, which offers 

unbeatable sustainability. 

Machining a wide variety of materials means constantly 

adapting to new challenges. The solution takes the form of 

universal milling cutters that can cope with steels, stainless 

steels and cast materials in equal measure. Alongside the 

targeted process efficiency, the aspect of sustainability is 

increasingly growing in importance. CERATIZIT shows how 

the two objectives can be reconciled – with the ProACT-Mill 

universal solid carbide milling cutter series. The milling 

cutters are manufactured from a particularly sustainable carbide, 

which CERATIZIT calls upGRADE. 

Full performance from 

99 % reprocessed raw material 

The upGRADE CT-GS20Y grade is the ideal choice for a wide 

range of applications. “What’s special about it is the significantly 

smaller carbon footprint generated during production, 

compared to carbides from conventional production. We 

achieve this by using 99 % reprocessed cutting tools as a raw 

material”, explains Michael Wucher, global technical product 

manager at CERATIZIT. Customers enjoy both economic 

and ecological advantages, thanks to a specific product carbon 

footprint (PCF). 

The test results of the new series underline its potential: 

ProACT-Mill milling cutters deliver up to 30 % higher performance 

compared to other universal tools. The newly developed 

coating, which brings with it additional performance 

and tool life reserves, further contributes to this. 

The new ProACT-Mill UNI and 

UNImax power milling cutters 

“With the ProACT-Mill series we’ve developed our most powerful 

tool for universal milling, packed with everything that 

modern milling cutters need – including CT-GS20Y, our most 

sustainable carbide grade to date”, says Michael Wucher. The 

variable helix pitch ensures extremely quiet running and 

optimum chip removal. The ProACT-Mill UNI has an HB 

shank for perfect force transmission, while the reinforced 

tool core ensures even force distribution throughout the 

milling process. 

To guarantee unbeatable cutting edge stability, the milling 

cutter has been given a radial clearance face. The face finishing 

chamfer promises top surface quality with base machining, 

while cutting edges with an irregular pitch specifically suppress 

vibrations. Ramping milling and helical milling are 

possible up to an angle of 30 °. Thanks to the impressive 

milling acoustics of the ProACT-Mill UNI (even with high 

infeed values and full-face milling), the machine room is 

never too noisy. 

The ProACT-Mill UNI with a cutting edge length of 3xDC 

is particularly suitable for series production and trochoidal 

machining. Innovative chip breakers in a radial design deliver 

the longest possible tool life and break the chips to a length 

of 1xD; these are then evenly and consistently removed due 

to the special shape of the chip space. Thanks to the minimal 

conical tool core, the 5-edge cutter runs very quietly even 

with a high lateral width of cut. 

When it comes to maximum material removal rates, the 

ProACT-Mill UNImax is the ideal solution. A special geometry 

design has been selected for this purpose – and is perfectly 

suited for depths of cut of up to 2xDC. The tool is available 

with HA and HB shanks for unbeatable force transmission 

and balance qualities. With the variable tool core, optimum 

force distribution was the key focus. 

Data Matrix Code has all the details 

All tools in the series bear a laser-applied Data Matrix Code 

(DMC), which can be used to call up the data of the “digital 

twin”. “This DMC contains all the information needed – once 

scanned, the tool can be correctly identified and its relevant 

technical data displayed. The customer can also see whether 

the tool is new or reconditioned, and how often it has already 

been sent to us for regrinding. And there is of course 

also a link to the online shop to make reordering quick and 

easy. We’ll be expanding the DMC functions in the future to 

deliver an even more comprehensive service”, reveals Michael 

Wucher. 

further information: www.ceratizit.com 



Innovative tools 

At AMB ZCC Cutting Tools Europe presented 

three new products, which drive lower costs and 

higher quality in a variety of manufacturing processes 

– the QF chip breaker, the zClamp Hydro 

hydraulic expansion chuck and the SMP09 side mill 

cutter. Turning, milling and reliable tool clamping 

are key issues in machining. 

Maximum control during 

precision machining operations 

The QF chip breaker is specially designed for low to very 

low cutting depths, making it ideal for use on sliding head 

lathe machines. The custom chip-forming elements provide 

for maximum chip control during finishing operations. 

In addition the positive rake angle helps to reduce 

cutting forces and vibrations, resulting in extremely good 

chip forming. With a peripherally ground cutting edge the 

QF chip breaker also guarantees a high level of precision in 

machining operations. In the case of thin-walled components 

the optimally prepared cutting edge reduces vibrations, 

which lowers the risk of damage to the surface and 

ensures a high-quality surface finish. 

At market launch the QF chip breaker will be offered with 

the high-performance PVD grade, YBG205H, which is extremely 

well suited for machining steel and stainless steel. 

The QF chip breaker is available in positive 7 ° geometries 

and includes the CCGT, DCGT and VBGT insert types. 

With its new QF chip breaker available in combination 

with the PVD grade YBG205H, ZCC-CT Europe offers a 

solution suitable for precision machining that has the potential 

to significantly increase the efficiency and quality of 

custom turning applications. 

New hydraulic expansion chuck 

Thanks to clamping forces of up to 2,000 Nm, the hydraulic 

expansion technology found in zClamp Hydro ensures 

that the tool is reliably clamped in place. Here the actuation 

piston is used to press hydraulic medium into the 

chamber system. The expansion sleeve loops evenly against 

the tool shank, which it first centers and then clamps over 

the entire surface of the shank. In order to maintain the 

clamping force oil and lubricant residue is pushed into the 

groove, keeping the clamping surface clean and free of residue. 

The chamber system is filled with hydraulic fluid, exerting 

a damping effect on the clamped tool. In this way, 

it is perfectly clamped in the center and features an ultra-high 

concentricity (< 0.003 mm) to guarantee the best 

surface quality possible. zClamp Hydro is able to guarantee 

tool stability at all times and as a result of this there is also 

less wear on the tool’s cutting edge. With the new tool 

holder the actuation screw can be tightened to the end 

stop without a torque wrench. This guarantees quick and 

reliable tool changes every time. 

The QF chip breaker, the zClamp Hydro hydraulic expansion chuck 

and the SMP09 side mill cutter 

The overall tool life is up to 40 % longer thanks to the hydraulic 

expansion chuck. Another handy feature is the ability to set 

the adjustable depth stop when clamping the tool. 

Adapter sleeves that come in a number of clamping diameters 

also ensure that zClamp Hydro is extremely versatile and 

therefore economical to use. Optional peripheral cooling along 

the tool shank is also available with the inserts, which has a 

positive impact on chip removal and tool life. 

further information: www.zccct-europe.com 

TRUST IN 

TECHNOLOGY 

70 % 

optimisation of the quality criteria 

for e-mobility gears compared to 

conventional components - 

process-reliable with KAPP NILES 

Scan QR Code 

and learn more.


PCD milling program for aluminum machining 

With over 30 years of experience in the development and production 

of precision tools made from ultra-hard cutting materials, Horn 

offers a comprehensive range of PCD milling cutters for productive 

machining of aluminum. During this time Horn has proven itself in 

numerous industries – and has thus become an important partner in 

the field of PCD tools. 

The new PCD milling program is part of this long-standing development 

and complements the portfolio. Based on market experience and customer 

requirements, Horn has methodically developed a complete standard program 

of milling tools. The standard series range DM20 to DM90 enables 

reliable machining of aluminum, non-ferrous metals and technical plastics. 

With a focus on resource conservation, customized cutting edge lengths and 

tool design, the tools are available from stock. 

With this product program, Horn offers a wide range of standard and 

special tools, from simple PCD end mills to complex and modular combination 

tools. As a driving force the focus is on economical, well thought out 

solutions with high productivity combined with Horn technology, flexibility 

and reliability. The Horn high-performance PCD grade consists of a sophisticated 

mixture of diamond grains of different sizes. As the volume percentage 

of diamond increases, so do the effective hardness, toughness and cutting 

edge quality. Strict quality standards and their control are a matter of 

course and ensure strong performance. 

Machining of aluminum 

The tensile strength, elongation, hardness and yield strength of aluminum 

can be influenced by alloying elements such as silicon, magnesium, copper, 

zinc and manganese. The material can become soft during machining 

due to heat development, stick to the cutting tool and even destroy it due to 

dis rupted chip flow. It is therefore important that the material and cutting 

With the new PCD milling program, 

Horn offers a wide range of standard and special tools, from simple 

PCD end mills to complex and modular combination tools 

The Horn high-performance PCD grade consists 

of a sophisticated mixture of diamond grains 

of different sizes 

parameters are properly matched. It depends 

on the aluminum alloy, the cutting tool, the 

cutting feed rate and speed, as well as the type 

and quantity of coolant. 

Aluminum is a versatile material that is 

used in all sectors of the economy. Supplemented 

by the new PCD milling program, 

Horn offers a broad portfolio of optimized 

tools for economical machining of the light 

metal. 

HORN tools for machining aluminum 

The most important features of HORN’s wide 

range of standard and special tools are special 

chip breaking geometries with sharp inserts, 

polished rake faces and coatings with 

very good anti-friction properties to counter 

the strong adhesion tendency of aluminum. 

Carbide inserts for grooving are ground peripherally 

to ensure extremely sharp inserts. 

For machining aluminum alloys with a high 

silicon content, the inserts are coated. The 

portfolio includes coated and uncoated circular 

tools and solid carbide cutters for milling. 

Single-edged milling cutters with a large 

chip space are also available for rapid metal 

r emoval rate based on high cutting data. Ultra 

hard cutting materials such as PCD and 

CVD-D with precision-lasered cutting edges 

are available for long service life or more complex 

work. MCD-tipped tools are used for 

high-polish machining of reflective surfaces 

or aluminum blow moulds, for example. 

further information: www.horn-group.com 



Quickly to a 

customized solution 

With its tool configurator (HTC– Horn tool configurator), Horn 

offers the possibility of supplying grooving tools in a short lead time. 

Horn focuses here on the grooving insert system 117. 

Following an enquiry from the customers, the HTC system offers the option 

of automatically generating a tool drawing of all insert profiles. This eliminates 

the lengthy design phase. The system enables quotations to be generated 

together with the technical drawing within 48 hours. Delivery time for 

tool holders and inserts is ten days from the time of order. 

Numerous cutting edge shapes and widths are possible for the grooving 

system. The inserts have a blank width of 8.5 mm (0.335") to 26 mm (1.024"). 

The tool system is mainly used for groove and gear broaching. Thanks 

to the Greenline process, Horn offers a delivery time of five working days. 

The number of pieces is limited to a batch size of fifty and is subject to the 

customer’s approval of the drawing. 

further information: www.horn-group.com 

With its tool configurator (HTC – Horn tool 

configurator), Horn offers the possibility of 

supplying grooving tools in a short lead time 

New catalog out! 

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Better chip control 

with laser geometries 

SIMTEK Präzisionswerkzeuge GmbH presented its 

range of tools with 3D-lasered chip forming geometries 

to specialists publicly for the first time at AMB 

in Stuttgart. According to the manufacturer, lasering 

the cutting edge geometry can sustainably improve 

production processes in metalworking and increase 

process reliability. A comprehensive selection of turning 

tools with 3D chip geometries was on display. 

“We have been working with our customers for decades to 

develop optimal tool solutions for specific applications, particularly 

in precision and micro machining”, explains 

Norbert Seifermann. The CEO of the Mössingen-based precision 

tool manufacturer SIMTEK played a leading role in the 

development of the new 3D laser technology. 

Years of development work lead to success 

The company has been investing heavily in the research and 

development of 3D-lasered chip forming geometries since 

2018. After five years and numerous tests, the tool specialist 

was able to produce high-precision 3D-lasered chip forming 

geometries in series production according to individual 

customer requirements outside of laboratory conditions. 

In the meantime tools with 3D-lasered chip forming geometries 

have also been implemented in the standard range. 

SIMTEK plans to include around 100 tools in the standard 

Diverse application 

scenarios: lasered 

chip-forming 

geometries show 

their strengths 

particularly in complex 

geometries, form tools with 

different machining directions or high form depths 

The simturn AX tool with 

3D-lasered chip forming 

geometry and internal 

coolant supply (not 

visible) enables the 

precise machining of 

deep grooves in valve 

cover housings, for example 

catalog range. In the future, the manufacturer intends to 

continuously expand its standard range with additional laser 

geometries. These have proven themselves in practice in various 

pilot projects over the last two years. 

“The introduction of laser geometries marks an enormous 

advance in tool technology”, Norbert Seifermann is certain. 

Individually designed and 3D-lasered chip forming geometries 

are the most effective and economical solution for optimum 

chip control. “Our tools are not only sharper and more 

precise, they are also able to reliably meet the requirements 

for chip control.” Long tool life and process reliability is not 

only of crucial importance in sectors such as the automotive, 

aerospace and medical technology industries. 

The optimum design of a 3D-lasered chip forming geometry 

is developed in coordination with the customer, taking 

into account the component and the respective process 

parameters (such as cutting speed, feed rate, cutting depth, 

etc.). Thanks to this, optimum results can be achieved when 

machining small diameters, running with high cutting 

speeds with a high heat input, high forming depths or longchipping 

materials, for example. 

Complex three-dimensional chip forming geometries: 

SIMTEK brought a wide range of grooving, longitudinal turning 

and boring tools with 3D-lasered chip forming geometries to AMB; 

this technology ensures improved chip control and 

increased process reliability 

The SIMTEK tool range currently includes over 11,000 

standard tools listed in the catalog. In addition several thousand 

individual tool concepts are created every year. The 

development and design expertise is extremely high and 

ranges from blanks to coating on own systems. Despite the 

large number of individual tool developments per year the 

company is known for its reliable delivery times. The target 

delivery reliability is over 98 %, which now also applies to the 

new 3D-lasered chip forming geometries. 

further information: www.simtek.com 


Six times higher metal removal rate 


The new RF 100 AL Micro from Gühring offers an 

outstanding combination of precision, efficiency and 

process reliability, making it the first choice when 

machining aluminum, copper and brass. With its 

innovative properties and superior performance, this 

tool raises the bar for micro-machining. 

The world of machining is changing: while some are working 

on ever-improving electric drives, others are striving to 

create lighter components to increase their efficiency. All of 

this means that the ISO-N group is currently considered one 

of the fastest growing material groups in the machining industry. 

The demand for specific tool solutions achieving the 

best possible performance is also increasing in the micromachining 

segment. 

With the RF 100 AL Micro, Gühring has now created a 

true high-end tool for these materials. The micro-precision 

milling cutter meets all relevant requirements with its performance, 

process reliability, burr-free finish and surface quality 

at the highest level. It achieves up to six times higher metal 

removal rates in rough machining than other products. 

No more built-up edges 

The RF 100 AL Micro has been specially developed for the 

high demands of machining ISO-N materials and offers exceptional 

performance and reliability. This allows the microprecision 

milling cutter to strike the perfect balance between 

soft, adhesive aluminum materials and high-strength alloys. 

The tool consists of an ultra-fine carbide substrate, which offers 

the optimum ratio of hardness and toughness for this 

material group. The special, ultra-thin Carbo+ coating significantly 

increases performance and, in combination with the 

exclusive GühroJet internal cooling, prevents material adhesions 

and built-up edges due to significantly improved chip 

removal. The user thus benefits from higher application parameters, 

a longer tool life and improved surface quality. The 

specially developed geometry of the milling cutter with its 

dynamic flute profile offers optimum stability and maximum 

chip space, which also increases machining efficiency. 

Tests show impressive results 

In extensive tests and applications the RF 100 AL Micro 

has delivered impressive results. When milling soft (3.3206/ 

AlMgSi0.5) and also high-strength aluminum alloys (3.4365/ 

AlZn5.5MgCu), the tool was able to achieve a reliable metal 

removal rate of up to 81.6 cm 3 , while other products achieved 

only 13.5 cm 3 . This corresponds to up to six times higher 

metal removal rates, which significantly increases production 

efficiency. 

Another development focus was on high running smoothness. 

The tool shows no tendency to swing up during either 

roughing or finishing. This produces excellent, streak-free 

surfaces with burr-free transitions on the component. When 

finishing with a lateral infeed of less than 5 % of the diameter, 

Ra values of 0.15 µm and above are to be expected, depending 

on the material, tooth feed and tool diameter. 

The fields of application range from the electronics 

industry with the production of circuit boards, sensor carriers, 

heat sinks to precision engineering, joint bodies, rail 

and sliding technology, as well as connection elements or 

end caps. This versatility makes the RF 100 AL Micro an 

indispensable tool for companies involved in the micromachining 

of ISO-N materials. 

Broad product range 

The portfolio of the RF 100 AL Micro includes four main 

types with a diameter range of 0.50 to 3.00 mm. The articles 

differ in corner radius and corner chamfer, as well as the 

length versions 2.5 x D and 5.0 x D cutting edge length. The 

variety of available diameter, length and corner radius or 

corner chamfer combinations allows the user to always select 

the most suitable tool for their specific requirements. 

The RF 100 AL Micro 

further information: www.guehring.de 


15


Innovation in the field of shoulder machining 

Boehlerit is expanding its portfolio of helical cutters 

to include new slip-on versions to complement the 

DELTAtec 90N Tang program. 

The DELTAtec 90N Tang 90 ° corner milling cutters are predestined 

for the medium machining of steel and cast iron 

materials and impress with a light cut and extremely stable 

cutting properties. The 4-edged indexable inserts guarantee 

high productivity and low tool costs. 

Boehlerit is introducing a new type of helical milling cutter 

that offers optimum chip evacuation, improved surface 

quality and smooth running thanks to its special design. The 

innovative milling cutter is perfectly suited for efficient 

shoulder machining and represents an economical alternative 

to existing helical tools. The roller end mill from 

Boehlerit has a newly conceived helical design that enables 

improved chip evacuation. This ensures a smooth machining 

process. The tried-and-tested uneven pitch of the tool helps to 

improve running smoothness and reduce vibrations. Available 

in slip-on versions with a diameter of 40 to 63 mm, the 

helical end mill from Boehlerit offers maximum flexibility 

for different applications. 

DELTAtec 90N 

Tang 90 ° 

With the special arrangement and overlapping of the indexable 

inserts over the helical rise, particular attention was paid 

to improved surface quality and smooth running. As a result, 

outstanding results are achieved even with larger cutting 

widths. “Our helical cutter sets new standards in shoulder 

machining and offers our customers an economical alternative 

to the popular tools already available in the DELTAtec 

90N Tang portfolio”, says Patrick Schwaiger, product manager 

milling at Boehlerit. 

further information: www.boehlerit.com 

Valuable tools for the collet industry 

The development started in 1969, exactly 55 years 

ago – for the first time, General Electric, back then a 

manufacturer of super abrasives, offered Borazon as 

an abrasive for the development of so-called boron nitride 

CBN grinding wheels and pins to the abrasives 

industry. 

Borazon, advertised as abrasive of a new era, with its extraordinary 

hardness and heat-resistance made it possible 

to grind hardened steels, starting from 58 HRC, faster and 

more efficient than ever before. 

LACH DIAMANT developed resin-bond Borazon CBN 

grinding wheels under the branding K-MX and tressex® for 

the grinding of HSS and hardened steels were, from the very 

start, so successful that they quickly took the place of conventional 

ceramic wheels, e.g. for tool grinding. 

One grinding task was immediately taken over by Borazon – 

internal cylindrical grinding! LACH DIAMANT developed 

G-MX grinding pins and internal grinding wheels with electroplated 

bonds turned out to be an immediate success, especially 

for the manufacturers of “collets”. To this day, LACH 

DIAMANT provides a large portfolio of Borazon CBN 

grinding pins and internal grinding wheels for all collet 

manufacturers, all immediately available from stock. 

G-MX Borazon CBN grinding pin, 0 6 mm, in a collet chuck 

The G-MX 500 program for internal grinding is available. 

Also in stock are diamond-coated internal abrasives for carbide 

machining. Depending on the application, all internal 

abrasives – diamond and CBN – as well as all produced 

grinding wheels can be delivered in special resin, metal and 

ceramic bonds. 

further information: www.lach-diamond.com 



The future is here 

Mitsubishi Materials has developed a very special 

series of grades that reaches across both milling and 

turning applications. The key feature of this innovative 

grades is due to the adoption of the newly developed 

AL-Rich coating method. 

turning grade MV9005 specialises in the high efficiency machining 

of heat resistant super alloys.4 

This advanced CVD coating of aluminum titanium nitride 

(Al,Ti)N is a compound of aluminum and titanium that is 

widely used as a coating for advanced cutting tools because of 

its extremely hard and heat-resistant properties. 

The combination of 

atoms with different 

sizes creates an 

exceptionally hard 

crystal structure 

The hardness of (Al,Ti)N increases as the Al content ratio increases, 

but with conventional technology, when the Al content 

ratio exceeds 60 %, the crystal structure changes and the 

hardness of (Al,Ti)N decreases. 

When the Al ratio is 

over 60 %, a softer 

crystal phase 

is formed 

Milling inserts 

Milling 

MV1020: this grade has advanced wear and thermal shock 

resistance and also achieves stable cutting at unprecedented 

cutting speeds, especially when machining steel and ductile 

cast iron, thus greatly reducing work time. 

MV1030: the new Al-Rich coating also provides excellent 

wear resistance. An unprecedented performance against sudden 

breakage was also realized especially during problematic 

wet cutting and when machining stainless steel. 

MV inserts are extremely versatile and are available for 

WWX, WSX, WJX, WSF, VPX, AHX and ASX cutters. 

By using a new coating process based on Mitsubishi Materials’ 

own original technology the Al-Rich coating does not change 

its crystal structure, even when the Al content is increased. 

This allows a higher Al content and provides higher hardness 

(Al,Ti)N. 

Crystal image of 

MV1000 series 

Turning 

MV9005: This grade 

exceeds all current 

standards when machining 

heat resistant 

super alloys. A range 

of negative and positive 

inserts and five 

different chip breakers 

ensure the optimum 

combination for efficient 

turning. Cutting 

speeds up to 110 m/min 

can be achieved. 

Turning inserts 

The MV1000 series includes two new grades for milling, 

MV1020 and MV1030 for machining a wide range of materials 

from alloy and stainless steels through to cast iron. The 

Negative geometry inserts CNMG, DNMG, SNMG, TNMG 

and VNMG types are available together with a 7º RCMT and 

RCMX positive geometry types. 

further information: www.mmc-carbide.com 


17


Three new “crazy” high-performance cutting tools 

Mikron Tool, world leader in micro-machining of 

difficult materials, presented three new solid hard 

metal tools for the AMB and IMTS 2024. The highperformance 

bit CrazyDrill Titanium TN/TK, for all 

types of titanium, and the two high-performance mills 

CrazyMill Cool CF and CrazyMill Cool SF, specially 

designed for delicate components. With these three 

products, Mikron Tool has set new benchmarks for 

high-performance micro-machining. 

“The madmen from Agno” have gone full throttle again: 

CrazyDrill Titanium TN/TK, CrazyMill Cool CF, and 

CrazyMill Cool SF are the latest high-performance micro 

tools from the Swiss-based tool manufacturer Mikron Tool. 

Over the past 25 years they have established new standards in 

the machining of difficult materials and won several industry 

awards for their Crazy Tools. 

Let’s start with the CrazyDrill Titanium TN/TK. This 

microdrill has been developed especially for drilling in all 

titanium alloys, including pure titanium (!), at diameters 

from 0.2 to 2 mm and depths of 3 x d and 6 x d. It can be used 

from 15 bar internal cooling already, so a high-pressure cooling 

lubricant system is not absolutely necessary. 

The design of the new CrazyDrill Titanium TN/TK microdrill 

includes the following features: 

The CrazyMill Cool SF 

has been developed as a 

superfinishing mill 

that produces milled 

surfaces at a grinding 

or polishing level 

of quality 

• a tip geometry tailored to all titanium grades, 

which guarantees a low axial cutting force and, 

together with the designed drill outer profile, 

ensures maximum drilling precision 

• polished grooves for reliable chip removal 

• coating specially designed for titanium material drilling 

This means the high-performance CrazyDrill Titanium TN/ 

TK bit is capable of drilling all titanium alloys and even pure titanium 

with high process reliability. The CrazyDrill Titanium 

TN/TK provides maximum feed rates, very long service life, 

optimal process reliability, and very high drilling precision. 

High-performance milling with excellent 

surface quality, up to ground finish quality 

Two new high-performance mills have been developed for 

milling applications. One is the “Chatter-Free” (CF) CrazyMill 

Cool CF and the other is the “Super Finishing” (SF) Crazy- 

Mill Cool SF. 

CrazyMill Cool CF – chatter-free 

The CrazyMill Cool CF is a high-performance micro mill 

designed for very high machining rates and capable of handling 

very challenging, delicate component structures. A 

perfect balance between cutting angle, clearance angle and 

cutting-edge conditioning results in a low radial cutting force 

and thus ensures the best form and squareness tolerances 

even at maximum depth of cut. 

Mikron Tool developed a high-performance drill for all types 

of titanium and two highly efficient precision mills, 

specifically designed for delicate components 

Its specific cutting geometry, combined with a dynamic 

milling process, makes it the ideal mill for delicate, thinwalled 

parts, or for parts that are not stable when clamped, 

which is a particularly common occurrence in the medical 

field (bone plates) and aerospace industry (structural components), 

as well as the watch industry. CrazyMill Cool CF 

is also very efficient, precise, and runs quietly when cutting 

grooves, insets, or other large volume machining tasks. 

The mill is immediately available in diameters from 

1 - 8 mm and two different full cutting lengths (3 x d and 4 x d). 



The CrazyMill Cool CF is a high-performance micromill 

designed for very high machining rates and capable 

of handling delicate component structures 

The CrazyDrill Titanium TN/TK microdrill has been 

developed especially for drilling in all titanium alloys, 

including pure titanium (!), at diameters from 0.2 - 2 mm 

and depths of 3 x d and 6 x d, especially under production 

conditions designed to work without high-pressure 

cooling lubricant systems 

CrazyMill Cool SF – superfinishing 

at less than Ra 0.3 µm 

The CrazyMill Cool SF has been developed as a superfinishing 

mill that produces milled surfaces at a grinding or polishing 

level of quality, with roughness of less than Ra 0.3 µm. 

This greatly reduces the effort required for polishing. The 

CrazyMill Cool SF also produces excellent surface quality of 

less than 0.3 µm in (chromium) steel, lead-free brass, copper, 

cobalt-chromium, and Inconel. 

The CrazyMill Cool SF is immediately available in diameters 

from 1 - 8 mm and two different full cutting lengths 

(3 x d and 4 x d). “Visitors at AMB and IMTS had the opportunity 

to explore the latest ‘crazy’ innovations at the Mikron 

Tool booth and even experience test workpieces firsthand. In 

short, the ‘Madmen of Agno’ are always eager to welcome 

users in search of ‘crazy manufacturing solutions.’ 

further information: www.mikrontool.com 

Platinum Tooling named North American distributor 

for Tecnicrafts 

Effective immediately, Platinum Tooling 

Technologies, Inc., will be selling products from 

Tecnicrafts Industries, a manufacturer of collets and 

guide bushings for Swiss Type CNC lathes. 

Tecnicrafts is an ISO 9001:2015 certified company, with its 

manufacturing plant in South India with state of the art machine 

tools and 115 technicians. Tecnicrafts collets and guide 

bushings are exclusively used for Swiss Turning applications 

on Citizen-Cincom, Tsugami, Star, Tornos, Hanwha, Traub, 

Hardinge, Manurhin-Kmx, Miyano, Nomura and other popular 

machine brands and are widely recognized and accepted 

by customers in Europe and Asia. 

Collets 

The collets are offered in steel and carbide lined versions with 

grooved, smooth, serrated bores in standard and Long Nose 

types. Tecnicrafts produces special collets such as V-Line, U- 

Line, Over-grip collets, for positive gripping of delicate parts 

without marks. The Ultra Precision (XP) W-Type collets are 

available for tool grinding applications on machines like 

Rollomatic, Anca, Ewag and others. Other collets offered includes 

5C and 16C types. 

Guide bushings 

Tecnicrafts guide bushings are generally offered in carbide 

lining having Super Finish bore with roughness value of 

less than 0.4 micron. These special guide bushings include 

U-Line, Extended Nose and Long carbide bores (Max Land) 

for special turning applications. 

Bar feeder collets 

The Bar feeder collets are available for various bar feeders like 

Fedek, LNS, Ikura-seiki, Iemca, Citizen, FMB and other popular 

brands. All collets and guide bushings are offered in Standard 

and Ultra-Precision grades. The bore profile includes 

round, square, hexagon, rectangular and profile bores as per 

customer drawings. 

Platinum Tooling Technologies, Inc., with its expertise in 

precision tooling and customer representatives throughout 

North America, is ready to meet the work holding tool needs 

for Swiss Turning applications with this new Tecnicrafts 

product line on its roster of quality tooling. 

further information: www.platinumtooling.com 


19

news & facts 

Setting an example for the future 

TIGRA is once again drawing attention 

on itself with an impressive investment 

in the future. The company has put 

a large-scale photovoltaic system into 

operation on the factory premises in 

Oberndorf am Lech – a sustainable step 

in the region. 

The ultra-modern system is spread over two 

areas: over 500 solar modules have been installed 

on the roof of the new production hall, 

and a much larger installation with over 2,000 

high-performance modules extends over the 

neighbouring open space. Together they generate 

an impressive total output of 1.5 MWh – 

enough to cover sustainably around 25 % of 

the company’s energy requirements. 

TIGRA paid particular attention to the protection 

and maintenance of the system. Not 

only were the open-space modules carefully 

fenced in, but the company also favoured a 

charming and environmentally friendly solution 

for grounds maintenance: sheep take over 

the natural lawn care under the solar modules, 

thus ensuring a harmonious interplay between 

technology and nature. 

This forward-looking project, the planning 

for which began in 2022, was successfully com - 

pleted August 2024 after intensive prepa ra tion 

and careful implementation. The investment 

Photovoltaic system on the factory premises in Oberndorf am Lech 

of a proud 1.5 million Euro is a clear statement: TIGRA wants to take responsibility 

not only economically, but also ecologically. 

All of the green electricity generated is used directly within the company, 

which significantly reduces dependence on external electricity supplies and 

lowers running costs. The fact that this sustainable energy source flows 

entirely into the company’s own operations is proof of the high in-house 

energy requirements that are permanently necessary for the production of 

high-precision carbide parts for the tool industry and the consistent focus on 

the use of green energy. 

With this initiative TIGRA is demonstrating how regional companies can 

actively shape the future – with a clear vision for sustainability and responsibility 

towards future generations. 

further information: www.tigra.com 

Strategic realignment 

The Fair Friend Group (FFG) has initiated 

a comprehensive strategic realignment 

to address the current global challenges 

in the machine tool industry and 

to strengthen its competitive position. 

CEO 

Dr. Sebastian 

Schöning 

CFO 

Rong-Rong Liu 

As part of this transformation FFG has appointed 

Dr. Sebastian Schöning as its new 

chief executive officer (CEO). Dr. Schöning, 

who holds a PhD in mechanical engineering, 

brings over 20 years of professional and management 

experience. Since 2021 he has served 

as the group’s chief operating officer and as 

CEO of MAG IAS GmbH. In his new role 

Dr. Schöning will spearhead global strategy 

development and lead the group’s operations. 

He will be supported by Ms. Rong-Rong Liu, 

who has been appointed chief financial officer 

(CFO) and will be responsible for overseeing 

the group’s financial management. 

A key element of the realignment is the increased leveraging of synergies 

among Fair Friend Group’s globally operating companies. This enables 

FFG to provide customers with even more integrated and customized solutions. 

Additionally FFG plans to expand its range of standard machines and 

develop new technologies in emerging industries such as humanoid robotics 

and energy. By deeply integrating artificial intelligence, smart manufacturing, 

energy effi ciency and decarbonization, FFG aims to ensure futureoriented 

and environmentally friendly production. Customers will benefit 

from a wide range of highly specialized machines and manufacturing 

systems, allowing manufactures to respond flexibly to both regional and 

global market demands. 

further information: www.ffg-ea.com 


news & facts 

New location in Mexico supports 

strong industrial growth 

On August 22, 2024, SCHUNK officially opened its 

new location in Santiago de Querétaro, Mexico. The 

building has its own assembly and manufacturing 

capabilities as well as a CoLab application center for 

automation and depaneling technology. 

This enables SCHUNK to serve the industry in North and 

South America with customized applications. The new location 

is geared towards future growth, so the company can 

be capable of responding to the increasing market demands 

with high flexibility and efficiency. 

The high-tech center Parque Tecnológico Innovación in 

Santiago de Querétaro, about 200 km north of Mexico City, 

is now home of SCHUNK. The new location will strengthen 

its global presence. The building, with an area of around 

5,000 m 2 , houses assembly and manufacturing capacities for 

the most important components and applications to offer 

regional and local customers specific solutions with particularly 

short delivery times. In addition the engineering capacities 

will be expanded at the new location and the CoLab application 

center for automation and depaneling technology 

will be put into operation. 

Industrial investment focus Mexico 

Mexico is a major investment destination for several key industries, 

especially in the automotive and electronics industries. 

International companies are expanding their activities 

here or planning to do so. SCHUNK is prepared to give 

support with appropriate, efficiency-enhancing production 

technology as well as engineering know-how and advice. 

Marcos Sepúlveda, general manager in Mexico, says: “We are 

now able to serve the needs of customers across the Americas 

In the new location in the technology parc of Santiago de 

Querétaro, 80 employees are now working to serve the 

North and South American markets 

with a particularly responsive approach. In the future we 

expect a higher demand for customized orders, which we will 

now meet with a strengthened on-site set-up.” 

Rapid growth is planned 

The location in Santiago de Querétaro begins operation with 

around 80 employees. To meet the anticipated strong demand 

and serve the local market with engineering, manufacturing 

and assembly expertise, rapid growth is planned for 

the coming years. Kristina I. Schunk, CEO of the company, 

says: “The strategic expansion in Mexico strengthens our 

global presence, as well as the future viability of our company. 

As in other regional markets we are focusing on building a 

network of partners hand-in-hand in Mexico to optimally 

serve our customers.” 

further information: www.schunk.com 

New member of the MAPAL Group 

The MAPAL Group has acquired X-Pro S.r.l., an Italian 

specialist for turnkey projects and fixtures. “X-Pro 

fits perfectly into the MAPAL Group”, emphasises 

Dr. Jochen Kress, president of the MAPAL Group. 

“We are a recognized specialist in the development of complete 

projects, with the focus so far being on our excellent 

cooperation with machine tool builders and on large-scale 

projects for the automotive industry.” With the expertise and 

know-how of X-Pro, MAPAL is creating additional capabilities 

to be able to offer projects quickly and comprehensively 

to customers in other focus industries as well. The company 

is thus meeting a global demand from potential customers, 

who want to completely outsource the design of machining 

processes to a reliable technology partner. 

MAPAL has been working successfully with X-Pro on the 

Italian market for several years. Claudio Gabos, chief sales 

officer of the MAPAL Group: “We are convinced that the 

acquisition of X-Pro will enable us to tap additional market 

potential even in these challenging times and generate momentum 

for further development.” 

X-Pro S.r.l. was founded in 2001 in Bologna, Italy, and 

employs about 35 people. Stefano Vitali continues in his role 

as managing director in charge of the organisation. 

further information: www.mapal.com 


21

news & facts 

LACH DIAMANT – 100 Years 

Tradition. Passion. Innovation. 

part 11: 

The question was: “If not now, then when?” 

LACH DIAMOND INC. is founded 

“When I held my first diamond in my hand in 1908, I would not have 

imagined that one day diamonds would not only be used in the automobile 

industry but also for the machining of wood and plastics”. 

Jakob Lach, the company founder, said this on camera in 1980. It 

would become the preface for the first presentation of a new technique 

for machining wood and plastics – using diamonds as cutting 

material – the Dia Tool. This video, with audio translated into multiple 

languages, has lost none of its relevance for the choice of appropriate 

tools within the furniture, flooring and composite industries; the 

video can be viewed at: https://bit.ly/LACHDIAMANT 

Should you, dear reader, have stumbled over the final sentence in my last article 

“The adventure diamonds love wood in America had begun”, perhaps 

with the thought: “Oh, I always thought that since 1969, LACH DIAMANT 

had risen to its position as an innovative partner of the automobile and 

supply industry with the development of Borazon T CBN grinding wheels 

for HSS tool grinding and grinding of high-alloyed steels, as well as, in 1973, 

with the manufacturing of the first polycrystalline diamond (PCD) cutting 

tools – but now wood?” Then my answer is: yes and no – let’s just try it. 

The following three trademarks illustrate and symbolize the 100-year-long 

entrepreneurial activity of the company Jakob Lach, founded by my father in 

1922: 

First, the brilliant, the cut jewellery 

diamond until 1960. Natural diamonds 

were cut in LACH diamond shops in and 

around Hanau with 600 employees. 

The industrial diamond from 1960 – 2000, was set 

in a holder and used for dressing conventional 

grinding wheels, and also served as a symbol 

for set polycrystalline diamond tools 

(PCD and PCBn) e.g. 

Symbol for all 

high-performance tools/milling 

cutters/drills etc. PCD/PCBn, CVD, Mono 

from 1979 until today. After the fusion of 

LACH-SPEZIAL-WERKZEUGE GMBH 

Company founder Jakob Lach, 1894-1984 

(photo taken in 1980) 

with the LACH DIAMANT enterprise on 

January 1 st , 2000, the entire portfolio of both 

companies was combined under this registered 

trademark. Included were traditional 

industrial diamond tools, diamond dressing 

tools, profiling and forming tools, “Dia- 

Fliese-perfect”, multi-point dressers, precision 

diamond dressing rolls, diamond and 

CBN grinding tools, diamond pastes and 

“Diamant-Spray MF”, as well as the entire 

LACH DIAMANT machine programme for 

the eroding of diamond PCD tools for the 

machining of wood and plastic, manufacturing 

and service, among others with the 

“Dia-2200-mini” … a long list of products, 

incorporating pioneering advancements 

which are state of the art technology today. 

The first steps in America 

It must have been for this reason that I felt 

compelled to venture out into America, a 

country unknown to me (see part 10 of this 

article series). 

Frankly speaking, I never had the intention 

to conquer this huge country all by myself 

with this new technology “Diamond 

for all wooden materials”. Remember what 

was said during the first presentation of 

LACH-Diamant tools for wood processing 

during LIGNA 1979 in Hanover: 

“Lach must have gone crazy – he wants to process 

wood with diamonds.” 

It was a blessing for the manufacturer of 

super-abrasives, General Electric in Columbus, 

Ohio. 


news & facts 

Technology, in this case LACH, had shown GE a way to expand 

the production of polycrystalline diamonds (PCD) and 

therefore make it finally more profitable. So far, PCD turning 

tools only required ONE diamond – however, milling cutters 

needed many more, depending on the number of teeth. 

So, it might not be surprising that I took this step with 

confidence. GE wanted to sell more diamonds (PCD), and 

LACH had not only the expertise but also the matching tools. 

In particular it was the diamond cutting tool (PCD) for the 

wood and plastic industry, superior to carbide, PLUS the 

know-how to manufacture these diamond-armoured tools. 

LACH DIAMANT’s key invention made this possible: spark/ 

electrical erosion “EDGplus®” (EDG = Electrical Discharge 

Grinding Technology). 

In short, LACH intended to bring this technology to 

the USA as well. After all we had the experience with such 

transfer of know-how (see part 9 of this article series, cues 

“Israel” and “Asahi, Japan”). 

There were interested parties – according to GE – in the 

United States; we intended to visit them individually. In for 

a penny, in for a pound. So we designed an ad and placed it 

in The Wall Street Journal on July 15 th , 1982: 

“CUTTING TOOLS Revolutionary new technology” 

With the help of my 

assistant Rita Stein- 

Junkuhn we put to– 

gether a travel route in 

order to visit approximately 

100 interested 

companies who had 

answered to our ad. 

My wife Margot accom 

panied me on this 

4-to-5-week strenuous 

journey from the US 

West coast all the way to 

Boston in New England 

in the East. We met 

Ad in The Wall Street Journal with the top decision 

makers in the management 

of all the companies we visited, ranging from conglomerates 

to medium-sized tool manufacturers. 

Apart from friendships which lasted for many years on 

a personal and business level, these answers showed that 

the American companies were not yet open to a successful 

project like ours at the time. By the way, during the later 

launch of the diamond tool in the USA, we encountered similar 

counter-arguments. 

Since the diamond tool was at least ten times more expensive 

than traditional carbide tools, critics stated that the diamond 

tool would not fit into the existing “3-months budget”. 

All arguments that the diamond tool had a 300-350 times 

longer tool life, were ignored. Interestingly this rejection 

came mostly from large scale industry companies; privately 

owned companies showed less resistance. 

After evaluating our tour, GE also agreed that we had to 

find another way for America. Chance played into our hands. 

Mr. Theo Leon, born in Belgium, applied in Hanau after he 

had completed his job as interpreter and marketing staff 

member at a major machine manufacturer in Cincinnati. 

He worked out a new marketing plan which considered the 

American mentality, and aimed for exhibiting at the next US 

wood tradeshow in Louisville, Kentucky, so that we could 

better reach and convince potential licensees. 

Up to the date of the Louisville show events moved at unprecedented 

speed. GE was of course in favour of this project 

– general manager Louis Kapernaros even suggested to 

generously support LACH. A few weeks before the event our 

employee Theo Leon succeeded in his search for Germanspeaking 

personnel for our tradeshow stand. That is how 

we met Karen Deutschler who had worked for an American 

bank in Frankfurt, and she and her husband now lived in 

the USA. We communicated frequently, and as a result, she 

was hired AND we founded LACH DIAMOND INC. as a 

Delaware corporation just a few days before the start of the 

Louisville show. 

Our presentations focused on our success and numbers 

since 1979 when diamond tools were first used in the wood 

and furniture industries in Germany, Italy, the Netherlands 

and Spain. Additionally we showed a selection of PCD tools, 

and wood and MDF/composite samples made with such tools. 

First experiences 

Even in hindsight, I must say that we could not have done it 

any better. My proposal focussed on licensing. Most reactions 

were something like “Sounds interesting, surely something 

for the future, maybe we can talk again in two years”, and I 

countered that “if you don’t participate in the market launch, 

how is the market supposed to develop in this direction?” 

Foundation document for Delaware Corporation 


23

news & facts 

LACH diamond tools at the first USA tradeshow in Louisville, 

well guarded by a sheriff 

Our tradeshow team, relaxing after an eventful day; 

left to right: Theo Leon, Karen Deutschler, Dieter Claus 

(product manager LACH-SPEZIAL-WERKZEUGE GMBH), 

my wife Margot Lach and me 

The decision was made. I would do the market launch 

myself; even major tool manufacturers in Germany had at 

that point no interest in expanding their carbide tool portfolio 

and adding “diamond”. 

At the Louisville show, the tradeshow stand became an 

attraction. Probably also because our exhibited diamond 

tools were moved back and forth on an LGB model train 

track, under the watchful eyes of an armed sheriff. 

Appearance: the Viking 

The good mood and motivation also carried over to our new 

friend, Mr. Matsui from the show in Los Angeles (see part 10 

of this article series) who was also exhibiting with his company 

HEIAN at the Louisville show. The president of his company 

had commissioned him to negotiate a licensing contract with 

LACH. Our meeting took place in a nearby Japanese restaurant 

where the tables were separated in typical fashion, with 

sliding doors made of tissue paper. 

In the midst of our lively and noisy discussion about the 

future of diamond, one of the sliding doors suddenly opened, 

without any advance warning. A stout, brawny Swede – much 

resembling a Viking – dashed to our table, “armed” with a 

piece of paper which he slammed on the table. “Carbide is 

always better than diamond” we read, and also noticed the 

terrified look in our Japanese friend’s wide-open eyes. The 

giant had slammed the sliding door and had disappeared 

without a word. Our lively, and so far promising, discussion 

ended abruptly, and – after a brief “retreat” meeting – we continued 

our talk on the edge of our bed in our hotel room. 

In the evening, we had an appointment in Lancaster, in the 

(allegedly) second-longest American western bar. Gigantic. 

Above three bars on the sides of the room I discovered a ticker. 

I was briefly distracted, and all of a sudden, I read a new text: 

“Diamonds are always better than carbide.” Who had done 

that? Deep breaths, okay, my wife … the evening and the day 

were saved. 

By the way, the first large presentation at the tradeshow 

in Louisville was excellent, and LACH DIAMOND INC. 

had been founded and celebrated its anniversary together 

with LACH DIAMANT Germany in September of 2022 – 

LACH DIAMANT in Hanau 100 years, and 

LACH DIAMOND INC. 40 years. 

Horst Lach 

“From now on, only LACH DIAMOND tools 

for mass production” – words from our very first enthusiastic 

customer, Bob Mitchell of August Lotz Company 

p.s.: you can read 

part 1 to 10 of this article series 

“100 Years LACH DIAMANT” 

here ☛ 

further information: www.lach-diamond.com 


news & facts 

Technology partnership driving 

cloud-based CAM automation 

ModuleWorks, a leading innovator in 

toolpath generation and simulation 

software for digital manufacturing, 

and Toolpath, a developer of a new 

cloud-based, AI-driven manufacturing 

workflow automation platform, have 

signed a multi-year technology partner - 

ship focusing on accelerated deployment 

of innovative cloud computing technology 

for machining estimation and CAM 

automation. 

The ModuleWorks and Toolpath teams outside 

the ModuleWorks office in Aachen, Germany 

The technology partnership focuses on accelerating the development of 

unique and innovative software solutions that automate tasks for shop 

owners, estimators, planners and CNC programmers. Since its introduction, 

the Toolpath platform – built using specialized optimization methods and 

artificial intelligence – has included proven technology from ModuleWorks. 

The extended technology partnership will focus on accelerating the performance 

of both companies’ software and the eventual integration of the full 

range of ModuleWorks functionalities into the Toolpath platform. 

Al Whatmough, CEO of Toolpath, explains: “Toolpath’s vision is to empower 

manufacturing professionals from the front office to the shop floor 

with a tool that, much like an autopilot in aviation, allows them to focus on 

higher value tasks as opposed to the time-consuming but necessary tasks 

of reviewing incoming RFQs, evaluating the machinability and viability of 

potential work, and then calculating the cost estimates based on real-world 

variables like their actual tooling and machining resources.” 

To accomplish their mission, Toolpath has already started building a 

strong network of advisors drawn from the broad machining community, 

and many of their executives have been actively engaged in the industry over 

the past ten to fifteen years. Additionally they are developing highly optimized 

algorithms and AI solutions. They are committed to delivering what 

machinists deserve and they trust ModuleWorks as a dedicated partner in 

their journey. 

“ModuleWorks and Toolpath have an aligned vision”, said Dr. Yavuz 

Murtezaoglu, founder & managing director of ModuleWorks. “We want 

to develop the best technology – empowering professionals in manufacturing 

– and get it to them fast. This is only possible with trusted partnerships 

and aligned software development. Because Toolpath has leveraged 

ModuleWorks technology from the beginning, we can move quickly to empower 

users with highly intelligent cloud-based manufacturing solutions for 

machining estimation and CAM automation.” 

further information: www.moduleworks.com 

Guill announces Guill Tool Europe 

Gerjan ter Wal 

sales manager Europe 

Guill Tool, the global 

leader in extrusion 

tooling, recently announced 

their expansion 

in the European market with the 

creation of Guill Tool Europe. 

They will offer a full line of Guill products, 

as well as sales and engineering support 

throughout Europe. Padraic Lunn Enterprises Ltd will continue to represent 

Guill in the UK. From concept design to engineering, manufacturing 

and supporting client processes, Guill has more than sixty years of experience 

in regular extrusion, multi-layered applications, jacketing, multi lumen, 

rubber, silicone and much more. The company maintains the highest quality 

standards regardless of application. 

Padraic Lunn Enterprises Ltd offers a full range of extrusion machinery 

and consultancy for all extrusion processes with a strong emphasis on tubing, 

wire, pipe and profile applications. The firm represents extrusion equipment 

companies in the UK, Ireland and other parts of Europe. 

With local sales representatives in each country, Guill looks forward to 

establishing a strong presence on the European continent. 

further information: www.guill.com 


25

processes 

A new level of flexibility in gear grinding 

KAPP NILES, a globally operating group of 

companies providing solutions for finishing gears and 

profiles, has reached a new milestone thanks to the 

new KNG 350 machine series. 

The KX 300 P gear center was already a true success story. 

The fact that more than 500 machines have been sold proves 

how successful the concept has been, with a combination 

of high flexibility and productivity. This is where the new 

KNG 350 series story begins. When designing this new machine 

platform, KAPP NILES took a look back at previous 

developments. Tried-and-tested solutions were adopted and 

further optimized, while adding new capabilities. 

This has led to a sophisticated modular system which provides 

a uniform basis for various machine concepts. Thanks 

to three different configurations for the tool and workpiece 

drive, the customers’ requirements can be catered perfectly. 

Flexible robot loading 

by means of intelligent components (smart tooling). Process 

monitoring, part tracing and inline quality assurance are 

available as an integral component for an industry 4.0 capable 

processing machine. 

The gear center has an excellent design (iF Design AWARD), 

and a view to further development concerning energy efficiency. 

The hydraulic functions, reduced to a minimum, are 

provided by a controlled pump unit, and pneumatic functions 

have largely been replaced by electric drives. Moreover, 

when considering the entire lifecycle of the machine, 

the switch from a machine base made of cast iron to one 

made of polymer concrete reduces the overall CO 2 

equivalent 

of the machine. These aspects being increasingly important 

to OEMs. 

KNG 350 flex gear center 

The machine concept 

The KNG 350 series is based on a compact, optimized set-up 

machine concept and is perfect for the job shop environment 

to large-scale series production of geared components with 

diameters of up to 400 mm. Thanks to the integrated ring 

loader, non-productive times are reduced up to 5 s, and bore 

parts as well as shaft-type workpieces up to 700 mm length 

can be auto loaded. The concept provides full flexibility when 

loading the components – from manual loading or simple 

pallet conveyors up to complex robot solutions. 

The functional and ergonomic machine design paired 

with the user-friendly interface KN grind supports the user 

during set-up and optimisation of grinding projects. A major 

aim was also to reduce non-productive times. So the series 

is characterized by short set-up times, which are achieved e.g. 

The assessment from the long-standing partner Scania in 

Södertälije/Sweden provides an example. Anders Urefors, responsible 

maintenance technician, has followed the technical 

evolution since the KX 300 P. He recently saw the KNG 350 

during the technical machine acceptance and was excited 

about the results. Things that previously had to be implemented 

upon individual customer requests have now become 

standard, like the height-adjustable operator panel. In addition, 

one is now much closer to the workpiece and tool axis 

when opening the operator door. Together with the quickchange 

systems for complete workpiece-dependent tooling, 

a new benchmark has been set for the machine set-up. It is 

immediately noticeable that ergonomics and usability were 

heavily emphasized in the requirements specifications during 

the development of the machine. “Lessons learned”, said the 

usually rather reserved Swede. 

KNG 350 expert 

The starting point for the new series was the expert machine, 

with an exclusive focus on the generating grinding of gears. 

The concept of a grinding spindle without counter bearing 


processes 

Especially when it comes to electrically driven commercial 

vehicles, there is currently a trend towards gears with greater 

diameters. While typical gear wheels for trucks used to 

have diameters of no more than approx. 300 mm, current 

components can reach diameters of up to 350 mm, or even 

400 mm in individual cases. The KNG 350 flex machine is 

also equipped to handle such cases thanks to the optional 

diameter extension. 

Optimum operability 

has already been proven in the DYNAMIC machines. The 

automatic HSK interface allows for a semi-automatic tool 

change, which is implemented consistently in both the expert 

machine and the other variants of this machine series. 

The machine features high-performance technology options, 

for example bias-free grinding of gears or, in order to meet 

greater surface requirements, by using combined grinding 

worms. Thanks to selectable dressing methods all requirements 

are met in a cost-efficient way, from single item production 

(topological dressing) up to mass production (multiribbed 

dressing). An integrated measuring device is available 

for all machines of this family. The probe allows for a complete 

gear measurement within the machine and is also used 

to cyclically measure definable gear characteristics. 

KNG 350 flex HS 

E-mobility presents new challenges when it comes to the production 

of gears. High power density in a compact space in pas - 

senger cars, and miniaturisation for complex bicycle drives 

often lead to challenging workpiece geometries for ma nufacturing. 

In the past the hard fine machining of gears with 

interfering geometries was primarily implemented by means 

of discontinuous profile grinding or gear honing, because the 

typical grinding worms with a diameter of 300 mm were too 

large for components with interfering contours. 

However compared to continuous generating grinding, both 

profile grinding and gear honing have disadvantages in terms 

of productivity, economic efficiency and consistent quality. 

In order to achieve high cutting speeds with smaller tool dia - 

meters, smaller grinding worms require state increased 

RPM. Previous machine concepts were not designed to meet 

the substantial dynamic requirements regarding tool and 

workpiece drives. 

The KNG 350 flex HS is characterized by superior grinding 

quality and productivity, even if such small tools are used. 

Thanks to a high-speed grinding spindle (HS) with a speed 

of 25,000 rpm even gears with interfering contours can be 

ground using tools with a diameter of at least 55 mm (generating 

grinding) or 20 mm (profile grinding). 

KNG 350 flex 

A bit bigger? When machine tool manufacturers ask this 

question, it’s not about getting bigger portion sizes for lunch. 

The performance-optimized grinding spindle with counter 

bearings allows cutting speeds of up to 100 m/s and is designed 

for the use of large grinding worms with widths of 

up to 200 mm. This allows an efficient realisation, especially 

when machining components with large modules and using 

2-sector worms for fine grinding or polishing applications. 

Using a standard tool, values of an average roughness depth 

Rz = 2.5 - 3 μm can be reliably achieved with continuous gener - 

ating grinding. For higher requirements the company offers 

tool sets with two different zones: one featuring standard grit 

and another designed for fine or polishing grinding, depending 

on the surface requirements. This makes it possible to 

achieve roughness values of Rz < 1 μm. The significantly increased 

bearing ratio of the tooth flanks boosts the maximum 

load capacity of the gear. Another advantage of this process 

is the integration into automated process chains with “onepiece-flow”, 

which was not possible with the vibratory finishing 

that was often used in the past. As a unique selling point 

polishing as a single technology is offered, for example in 

order to only polish gears after shot peening. 

Various tool axes of the KNG 350 series 

Two further aspects highlight the flexibility of this machine. 

Due to the use of auxiliary spindles very small grinding 

wheels with the minimum root circle of the gear to be grind 

can be applied. The integrated set-up ratio enables a cutting 

speed of up to 50 m/s even with a grinding wheel diameter of 

30 mm. Both involute internal gears and special profiles can 

be machined with the internal grinding device. Thanks to the 

new quick-change interface, auxiliary spindles and internal 

grinding arms can be directly and quickly set up on the tool 

spindle. 

External and internal gears of small and large workpieces 

can be machined both by generating grinding and profile 

grinding, depending on the application, with dressable 

corundum or non-dressable CBN tools. 

This machine type truly deserves the name “flex” and 

leaves nothing to be desired in terms of gear grinding. 

further information: www.kapp-niles.com 


27

processes 

Centerless grinding rethought 

Innovative machining concept for thin-walled round workpieces 

When bearing manufacturers are 

looking for a machining solution that 

delivers maximum precision with repeat 

accuracy and is also economical, all roads 

lead to Switzerland. One of the companies 

based there is the grinding specialist 

Kellenberger, whose production concept 

on a VOUMARD 1000 has completely 

won over leading companies in the bearing 

industry. 

When it comes to precision machining of 

thin-walled sleeves or rings that are to be 

ground internally and externally in a single 

clamping operation, an intelligent clamping 

solution is required above all. This is because 

thin-walled workpieces, such as roller 

bearing rings, must not be deformed during 

clamping. At the same time the clamping system 

must ensure absolute concentricity of the 

outer dia me ter to the inner diameter during 

machining. 

The most obvious clamping solution is of 

course a magnetic chuck, which serves to 

fix the workpiece on the face side and generates 

the workpiece speed. However especially 

with thin-walled rings with a very small contact 

surface to the magnet, it can be difficult 

to build up the necessary static friction so that 

the workpiece is not pushed out of position by 

the grinding forces. The workpiece must also 

be centered on the chuck, which takes quite 

some time and requires operator intervention. 

To counter this, two adjustable support shoe 

devices are used to keep the workpiece centered 

in rotation during the grinding process. 

They also counteract the grinding force 

exerted by the grinding wheel and the force of 

gravity. This variant of centerless grinding is 

known as “shoe-type centerless grinding”, but 

is casually called “shoe grinding”. 

Exemplary clamping device for bearing production: 

magnetic chuck and support shoe device 

direction, the workpiece is supported by the shoe fixtures, which enable very 

precise positioning and support. The workpiece can therefore be inserted 

without alignment. The rotation of the workpiece during machining results 

in a stable position. 

The front shoe (support shoe) supports the workpiece in front of the grinding 

area and absorbs the weight forces. The rear shoe (measuring shoe) supports 

it behind the grinding area and defines the component diameter. This 

additional support enables greater dimensional accuracy and surface quality. 

It also allows the workpiece to be changed quickly, which can also be done 

automatically. 

Voumard 1000 

Shoe-type centerless grinding is a special 

variant of centerless grinding. It enables, 

for example, precise machining of the outer 

and inner form surfaces of bearing rings in 

one single clamping operation. In this process, 

the magnet forms the stop for the workpiece 

in the axial direction, as in normal 

work with the magnetic chuck. In the radial 


processes 

Unique machine concept: 

the patented B2-axis with table turret of the VOUMARD 1000 

Michael Egeter, head of design at Kellenberger, sees the 

design of the VOUMARD 1000 as the ideal prerequisite 

for fully exploiting the advantages of shoe-type centerless 

grinding in bearing production: “The machine concept of 

the VOUMARD 1000 combines the proven features of the 

Voumard machines, which today are still in use in many 

companies, including bearing manufacturers, with significant 

innovations that we have introduced in the new design 

of the VOUMARD 1000. It is optimized for flexible, universal 

internal and external circular machining of complex 

workpieces up to a length of 600 mm. The variety of workpieces 

ranges from the smallest individual parts for injection 

systems in car engines, ball bearing rings and gears to 

hydraulic and complex components in tool and machine tool 

construction.” 

Like the Kellenberger machines, the VOUMARD 1000 has 

hydrostatic guides in all axes. These highly dynamic linear 

axes are backlash-free for positioning accuracies in the nano 

range. This means that workpieces can be ground extremely 

precisely with maximum repeat accuracy and machine 

availability over the entire service life of the machine. Minimal 

maintenance costs, improved machine availability, and 

greater contour accuracy and process reliability are further 

advantages.” 

High flexibility due to 

two B-axes and grinding spindle head 

The special features of the VOUMARD 1000 are the two 

high-precision hydrostatic B-axes: B1-axis with spindle turret, 

B2-axis with table turret. The two swiveling B-axes also carry 

out all the necessary movements of the dressing and measuring 

devices. The spindle turret on the B1-axis is equipped 

with a uniquely compact grinding spindle head with a flexible 

grinding spindle arrangement. Spindles and measuring 

sensors can thus be optimally positioned and allow the 

machining of almost any workpiece shape as well as the execution 

of several internal and external grinding processes 

in one single clamping. When grinding roller bearings, the 

grinding head is equipped with an external grinding wheel, 

an internal grinding spindle and a measuring device. 

The high-precision hydrostatic B-axes and the exceptional 

stability of the machine were ultimately decisive, and fully 

won over the customer. During the factory visit in Goldach, 

Switzerland, the requirements for the grinding process for 

the bearing rings were specified once again and the dimensional 

accuracy, roundness and cylindricity were defined. 

The required dimensional accuracy in the outer diameter 

is D100 ± 2 µm / D40 ± 1.5 µm, in the inner diameter 

D100 ± 2.5 µm / D40 ± 2 µm. Required roundness inside and 

outside < 0.7 µm and cylindricities of < 1 µm. Another require - 

ment was the ability to measure during grinding (in-process 

measurement). This was also fulfilled with the innovative 

design of the spindle head and clamping device. The tests at 

Kellenberger resulted in form accuracies during dressing 

(without radius dresser) of < 1.5 µm, form accuracies of the 

bearing running surfaces of < 2 µm (with forming roller), 

< 1.5 µm (with radius dresser) and a coaxiality of < 2.3 µm, 

thus meeting the requirements for the geometry fully. 

“Our customers had already had very good experiences with 

the special grinding machine manufacturer USACH, which 

is part of our group, and also with the Voumard machines 

that were already in operation at the factory”, Kellenberger 

CSO Marcel Hollenstein explains. “From a technical point of 

view the flexibility and collision-free nature of the kinematics 

concept, and the two hydrostatic B-axes were particularly 

impressive. And of course, the accuracy of the process. 

Satisfaction was also very high in terms of sales, engineering 

support and service. He adds: “Although we were at the 

upper price limit with the VOUMARD 1000 and our innovative 

clamping device design, we were awarded the 

contract for several machines. Our concept was convincing 

right down the line.” 

further information: www.hardinge.com 


29

processes 

Roadmap for the decarbonization 

of grinding processes 

Development and grinding technical investigation of a 

vitrified bond formulation for low-temperature firing 

written by Dr. Alexander Nashed (Senior Research Engineer), Jörg Rucker and Lutz Gaida 

Saint-Gobain Abrasives GmbH 

Industrial companies throughout Europe are 

currently busy identifying potential for massive CO 2 

savings and getting closer to their defined scope 1 

and scope 2 targets through optimized processes. The 

Saint-Gobain Group – and with it the abrasives specialist 

Saint-Gobain Abrasives – is no exception. The target: 

by 2030 the aim is to achieve a 33 % reduction in 

emissions for scope 1 and 2 (direct and indirect) and 

a 16 % reduction in scope 3, i.e., across the entire value 

chain (absolute reduction compared to 2017). The target 

for 2050 is “net zero carbon”! This way all process 

steps are being examined for any potential for optimization 

and conversion. Saint-Gobain Abrasives has 

now taken a decisive step by almost completely switching 

from high-temperature to low-temperature bonds 

in vitrified bonded abrasive tools. 

If the ambitious targets set by the European Union and 

others are to be achieved, three pillars must be considered 

in parallel and driven forward accordingly: 

➢ decarbonization of customer processes 

➢ development and distribution of 

maximally sustainable product solutions 

➢ massive reduction in CO 2 emissions 

during their production 

At Saint-Gobain Abrasives the question arose early, as 

part of the research and development work in the Grinding 

Technology Centre Europe (EGTC) in Norderstedt near 

Hamburg, on how to noticeably increase the energy efficiency, 

particularly in the production of vitrified bonded grinding 

tools. Looking at the usual firing temperature range for vitrified 

bonds, which is between around 900 ° C and 1260 ° C, it 

quickly becomes clear that the greatest potential, the greatest 

impact on scope 1, lies in reducing the firing temperature and 

therefore the (gas) energy supply. Accordingly it makes sense 

to replace all high-temperature bonds (HT) in the product 

portfolio of conventional grinding tools, which are generally 

manufactured in the upper temperature range, with low-temperature 

bonds (LT) – while retaining both the mechanical 

properties and the required grinding behaviour. 

Saint-Gobain Abrasives launched the first vitrified LT bond 

back in 1985 and has been developing new solutions exclusively 

based on LT since 1990, building up a wealth of experience 

in this area over the years. The obvious next step was to 

replace all HT bonds in Europe as completely as possible by 

the end of 2023. 

To realize this project a general approach was pursued that 

takes all relevant physical properties into account in the development 

of the vitrified LT bond formulation and generates 

reliable and representative results in the subsequent grinding 

investigation. 

Aspects of the development of LT bonds 

When manufacturing vitrified bonded abrasive tools it is 

essential to match the bond chemistry to the respective application: 

network formers, network modifiers and intermediate 

oxides, for example, have a direct influence on the physical 

properties of the bond, such as its strength, melting and 

crystallization behaviour. Therefore they also influence the 

mechanical properties and performance of the finished 

grinding wheel. The mechanical properties considered include 

modulus of elasticity, flexural strength, hardness and 

density – these should be in the same range as the reference 

wheel containing the HT bond. 

Approach to the grinding inspection 

The main task of the EGTC was to develop a grinding 

method in which different grinding parameters are used to 

determine characteristic values that enable a comparative 

analysis of the grinding tools. By selecting different workpiece 

and grinding wheel specifications, a wide range of applications 

was mapped, which can be processed in a timeefficient 

manner using the aforementioned methos. During 

the tests at the EGTC the following data was measured and 

analyzed in detail: 

➢ power consumption of the grinding spindle 

➢ grinding wheel wear 

➢ material removal 

➢ surface quality R a and R z 

To ensure the (geometric and dynamic) comparability of the 

results, the following values were kept constant: 

➢ equivalent diameter d eq => 

constant contact length l g at related infeed a e 

➢ workpiece speed v w 

➢ cutting width a p 

➢ cutting speed v c 


processes 

Experimental setup and execution 

For the tests at the EGTC external cylindrical plunge grinding 

was selected, whereby the plunge cuts were carried out 

with defined grinding parameters on four workpiece blanks 

of the same quality. Seven different wheel specifications from 

hard to soft were tested on three different workpiece qualities. 

Grinding was performed in counter direction and two different 

material removal rates were run per specification in order 

to load the grinding wheels to different levels of stress. 

ensure that the spindle power consumption increases sharply 

in the normal case during the initial cut and to avoid premature 

loss of performance of the grinding wheel. On the other 

hand the wheel should not be dressed too roughly to ensure 

that the quasi-stationary working window is reached quickly 

(in plunges two to four). Based on extensive preliminary tests 

and empirical data from research, the following parameters 

were therefore established for a suitable "dressing method": 

About the grinding method 

As already mentioned, a moderate specific material removal 

rate of 3.2 mm 3 /mms and a high specific material removal 

rate of 7.5 mm 3 /mms were selected. When selecting the specific 

material removal rates care was taken to ensure that 

grinding was neither carried out at a too low radial feed rate 

(high specific grinding energy) nor at a too high radial feed 

rate. Because too drastic radial feed rate leads to increased 

grain pull-out and excessive wear of the grinding wheel. A 

cutting speed of 45 m/s was identified as a standard cutting 

speed for customer processes. It should also be mentioned 

that a total infeed of 3.0 mm was sufficient to cause significant 

wheel wear. The following diagrams show examples of 

spindle power measurements at moderate (left) and high material 

removal rates (right). 

The grinding wheels have a width of 10 mm, the blanks of 

5 mm. The plunge is done in the center of the grinding wheel 

width so that wear creates a measurable profile on the grinding 

wheel. The plunge into the first blank is done with 1/10 of 

the total infeed, plunges two, three and four are each done 

with 3/10 of the total infeed. After each plunge the wheel profile 

generated by wear is projected onto a graphite coupon, 

which is then measured optically in order to record the radial 

grinding wheel wear. 

Using this method the initially high grain protrusion 

caused by dressing can be reduced to such an extent that a 

load is applied to the bond at the plunges in blanks two, three 

and four, which has a dominant effect compared to the grain 

wear. This ensures that the grinding wheel ideally reaches its 

quasi-stationary working window at blanks two to four and 

therefore grinds outside the uncontrolled statistical range. 

In addition the measured values can be correlated with each 

other after each plunge, which also makes it easier to analyze 

the development of the measured values within the overall 

infeed. 

Workpiece selection 

For the grinding tests, two LT specifications per workpiece 

were always compared with an HT reference wheel. In order 

to compare the behaviour of the wheel specifications, three 

different workpiece qualities with different grindability were 

defined: 

About the dressing method 

The speed quotient q d , the infeed a ed and the overlap ratio U d 

are the main factors influencing the topography of the grinding 

wheel generated during rotary dressing. These parameters 

were selected so that the grinding wheel is rough enough 

(with correspondingly low grinding forces at the start) to 


31

processes 

The following example shows that the comparatively easier-to-grind bearing 

steel can be ground by the tested grinding wheels of the specification with 

the hardness and structure “I8” without any issues up to the last blank, so 

without a drop in spindle power or an increase in wheel wear. In the case 

of carbon steel all wheels reach their performance limit at the fourth blank, 

while this limit is already reached at the second blank in the case of high 

chromium steel with difficult grindability, resulting in high wheel wear and 

a significant drop in spindle power. 

*The tests on the 100Cr6 were carried out with ten (instead of four) plunges, 

whereby the first plunge, analogous to the tests on the C60 and X100, was carried 

out with 1/10 of the total infeed on blank #1; blanks #2, #3 and #4 each received 

3/10 of the total infeed, also analogous to the tests on the C60 and X100 

Selection of the grinding wheel specifications 

The seven investigated specifications were selected according to different 

structures (open, medium, closed) and grades (soft, medium, hard) in order 

to represent different grain retention forces. This ensured that a representative 

spectrum of specifications was analyzed and mapped. In the example 

shown, all wheels from soft (I8) to hard (Q5) show almost optimum stock 

removal at both material removal rates on the 100Cr6 workpiece: 

➢ the harder the grinding 

wheel, the higher the 

power/energy/force 

➢ good cutting behaviour 

for all specifications 

➢ soft specification (I8) 

shows optimum removal 

It can also be seen that the selected specifications, which differ in their grain 

retention forces, also operate at different specific grinding energies, as shown 

in the following diagram: 

The grinding energy increases with increasing grain retention forces or – in 

other words – with increasing hardness and density of the grinding wheel, 

which means that the harder wheels (red and 

green) have a higher energy consumption in 

order to remove an equivalent volume. It is 

important to note that the harder wheels tend 

to reach their performance limit earlier on the 

more difficult-to-grind workpieces (C60 and 

X100) than softer wheels, as the latter have a 

higher cutting ability. 

Differentiation of 

equivalent grinding wheels 

When it comes to the question of which HT 

bond is optimally substituted by which LT 

bond in which application, a wholistic view is 

required, considering all measured data and 

observations. All three workpiece qualities 

must be taken into consideration, as the following 

example illustrates. The soft specification 

with the hardness and structure “I8” was 

tested on the three different workpiece materials 

presented. The red bars in the diagrams 

represent the reference HT grinding wheel 

with the bond designation VC.1, the blue 

and green bars represent the two LT grinding 

wheels of the same specification with the 

bond designations VC.2 and VC.3. 

The Grinding Technology Centre Europe 

(EGTC) of Saint-Gobain Abrasives 

Since 2001 the Grinding Technology 

Centre Europe (EGTC) in Norderstedt near 

Hamburg has played a key role in the development 

of innovative grinding solutions to 

support the customers of Saint-Gobain 

Abrasives GmbH. In addition to the development 

of new process technologies for 

diamond, cBN and bonded grinding tools, 

a further focus is on application technology 

research and the dialogue with experts and 

end users, with the clear aim of offering 

customers modern, sustainable grinding 

solutions that are tailored to their processes. 

As one of Saint-Gobain Abrasives‘ four 

Grinding Technology Centres worldwide, the 

EGTC in Norderstedt plays a fundamental role 

in the design and investigation of innovative 

grinding solutions and technologies for all 

product families. Together with end users, 

machine manufacturers and various scientific 

institutions, new grinding solutions are 

developed and optimized there. Trendsetting 

customer-specific application projects 

are also regularly launched in Norderstedt. 

In addition the EGTC offers a wide range of 

seminars and training programs to facilitate 

a practice-oriented transfer of knowledge for 

industrial grinding processes – supported by 

measuring technology, the latest generation 

of grinding machines and state-of-the-art 

training technologies. 


processes 

*The tests on the 100Cr6 were carried out with ten (instead of 

four) plunges, whereby the first plunge, analogous to the tests 

on the C60 and X100, was carried out with 1/10 of the total 

infeed on blank #1; blanks #2, #3 and #4 each received 3/10 

of the total infeed, also analogous to the tests on the C60 and 

X100. 

With the 100Cr6 bearing steel, both the HT reference 

wheel and the two LT wheels show a stable spindle power 

curve and only low wheel wear as well as similar material 

removal – a differentiation is therefore not yet possible 

at this point. Accordingly it is necessary to analyze 

the grinding tests with analogous engagement conditions 

on the C60 and X100 workpieces, which are more 

difficult to grind. This shows that with carbon steel C60 

there is a drop in spindle power from blank 3 onwards 

and thus correlates with higher wheel wear. In the case 

of the high chromium steel X100 a similar spindle power 

curve can be seen, but this results in a more intense decrease. 

This is accompanied by even higher wheel wear. 

Furthermore it can be seen that the VC.2 grinding 

wheel with the highest material removal in the grinding 

process produces intense chatter marks on the X100 

workpiece, which also correlates with the consistently 

higher spindle power of this wheel. Therefore, in this 

specific case, the wheel with the second-highest material 

removal (VC.3) should be selected as a substitute, 

as this corresponds to the grinding behaviour of 

the HT bond. No chatter marks occur here and at the 

same time the wheel wear is significantly lower, compared 

to the HT grinding wheel. A further argument is 

the fact that the HT reference wheel operates at almost 

the same level of spindle power as the VC.3 and therefore 

a very similar energy consumption can be expected. 

Based on the results obtained in this way, Saint-Gobain 

Abrasives could replace almost all vitrified HT bonds 

with LT bonds by the end of 2023 without any loss of 

performance. An exception are (still) a few specialty 

products, which only account for 3 % of the total range. 

Summary 

The tests were carried out over a period of five months and 

were designed to ensure the comparability of the bond systems 

and maximize time efficiency: 

➢ same engagement conditions for all trials 

➢ test setup with high reproducibility 

➢ dressing and grinding parameters for 

rapid attainment of the quasi-stationary 

grinding window 

➢ internal grinding investigation with around 230 trials 

➢ supplemented by external trials at customer sites, 

accompanied by application engineers (the results 

obtained there were in line with the internal trials) 

The results are therefore characterized by a high level of conclusiveness 

and were also validated comprehensively with the 

support of other Saint-Gobain Grinding Technology Centres 

regarding different grinding applications. Hence, a complete 

representation of different grinding conditions could be 

reached as much as possible. 

The most important fact at the end: 

By almost completely replacing HT bonds with LT bonds, 

the Saint-Gobain Abrasives GmbH was able to reduce CO 2 

emissions from production in Europe by around 1,700 

tons per year, and gas consumption was reduced by around 

800,000 m 3 per year. Another important step towards achieving 

the ambitious scope 1 and scope 2 targets! 

further information: www.nortonabrasives.com 


33

processes 

High-performance micro-milling 

of high-hardness steels: e.g. for bipolar plates 

Tools for punching, embossing and 

forming sheet materials are very demanding. 

Accuracies in the range of 

1-2 µm are sometimes required during 

production. The challenges increase the 

larger the tool and the thinner the sheet 

metal is. A prime example of these difficulties 

can be experienced in the production 

of stamping plates for the sheet 

metal shells for so-called bipolar plates 

for hydrogen fuel cells. 

Speakers, left to right: Marc Maier (Open Mind), Dr. Oliver Gossel (Röders), 

Matthis Toppmöller (Hufschmied), Marc Geile (Voestalpine/Böhler), 

Matthias Schneider (Zeiss), Herbert Merz (MHT),Marco Giarrusso (Open Mind) 

(photo: Klaus Vollrath) 

Filigree channel structures on a demonstrator 

(300 x 150 mm) for an embossing die for bipolar 

plates for automotive fuel cells 


These thin hollow structures are made from 

welded sheet metal half-shells enclosing filigree 

flow channels. Together with the membrane 

electrode units sandwiched between 

them, numerous layers are arranged in regular 

order in so-called “stacks”. 

Sample workpiece (50 x 40 mm) with various 

surface structures typical of bipolar plates 


Politicians want to replace fossil fuels by promoting and favoring renewable 

forms of electrical energy. But since some tasks cannot be mastered 

using electricity alone, the development of a hydrogen economy is also being 

promoted. The fuel cell is thus seen as an alternative to the battery. This involves 

the use of so-called bipolar plates, which in the automotive sector consist 

of stamped, embossed and welded sheet metal half-shells forming hollow 

bodies. The bottleneck of this technology is currently the production of the 

required forming and punching tools. Thinner sheet metal would help to 

reduce the mass of the fuel cells. However, the thinner the material, the narrower 

the cutting gap the more precise the geometry of the tool must be. 

The accuracies to be achieved by the embossing and punching tools and the 

presses pose extreme challenges. 

This requires the development of specifically adapted process chains for 

the manufacturing of embossing and punching tools for producing suitable 

sheet metal parts. Key aspects are the steel for the tools, the CAD/CAM software, 

the micro-milling tools, the properties of the machining center, the 

lubrication and cooling of the milling cutters and the metrological control 

and documentation of quality control. The companies Hufschmied, MHT, 

Röders, Open Mind, Voestalpine and Zeiss have joined forces on this project. 

The results currently achieved were presented at Hufschmied during a 

seminar with more than 50 participants. They are not only interesting for 

the core topic of “bipolar plates”, but also offer promising insights for other 

sectors such as micro-production, precision mechanics, medical technology 

and aerospace. 

Ultra-hard steel: Böhler K888 Matrix 

In order to economically achieve the extremely fine structures of such 

bipolar plates, the embossing tool must have very high dimensional accuracy, 

good wear resistance and a low tendency to stick. Another prerequisite is 

good machinability. This requires a low proportion of primary carbides in 

a hard microstructure matrix (“matrix steel”). The carbides should be tiny 

and homogeneously distributed over the entire volume, as coarse specimens 

could break during machining and thus cause surface defects. This implies 

resorting to steels produced using powder metallurgy. Böhler K888 Matrix, 


processes 

a material with a maximum carbide content of < 2 %, was 

selected. It is supplied in the soft-annealed condition with a 

Brinell hardness of < 280 HB and achieves a Rockwell hardness 

of 63 +1 HRC after hardening at temperatures between 

1070-1120 ° C. It is characterized by high wear resistance even 

in comparison with materials with a much higher carbide 

content. Machining tests at Hufschmied have shown that the 

material is nevertheless easy to machine and that very good 

surface qualities can be achieved. The material is also easy to 

coat, which also results in prolonged service life. 

CAD-CAM software 

A perfect NC program is essential for optimum workpiece 

quality. With its hyperMILL CAD/CAM system, OPEN MIND 

offers all the prerequisites for creating these NC programs. 

The software calculates the toolpaths with the utmost accuracy 

and thus delivers correspondingly precise NC data. A 

few points should be given particular attention to. In order to 

fully take into account the topology of the component when 

calculating the toolpaths, geometric features such as sharp 

edges, gaps and the nature of the surface transitions have to 

be analyzed and recognized. These inputs are considered in 

the calculations and control the point distribution in the tool 

path, for example. Further optimizations such as adjusting 

the feed rate are possible. This allows the milling tool to machine 

the component at a constant feed rate. A “smooth overlap” 

function avoids visible transitions resulting from the use 

of different milling tools or strategies and reduces the expenditure 

required for manual reworking to almost zero. 

Another important feature makes it possible to link geometrically 

identical structures within a component, which 

are recognized or defined either automatically or manually. 

The corresponding toolpaths, which were first created for 

a single area, can then be brought to the previously recognized 

or manually defined positions via a transformation and 

linked fully automatically. Superfluous movements are eliminated 

in the process. This considerably reduces the computation 

times in the CAM system. 

Requirements for the milling machine 

The machining of embossing dies for bipolar plates is characterized 

by high material hardness, small milling cutters 

with diameters well below one millimeter, high demands on 

surface quality and accuracies down to the 1 µm range. The 

multiple small contour details also result in long machining 

times, thus requiring very good long-term thermal stability 

of the machine tool. 

Röders’ machine tools are particularly suitable for such 

precision machining tasks. Among other things they are 

characterized by frictionless direct drives, highly rigid roller 

guides, frictionless weight compensation of the Z-axis, precision 

HSC spindles and highly accurate tool measurement. An 

outstanding feature is the extremely high control cycle rate 

of 32 kHz in all control loops, which enables rapid correction 

of even the smallest deviations. Another decisive factor 

is the sophisticated temperature management by means of a 

temperature control medium that is kept stable at ± 0.1 K and 

circulates through all key components of the machine. This 

makes it possible to reliably maintain tolerances in the lower 

micrometer range. 

The tools of the Bumble-Bi series made by Hufschmied used to 

process the various segments of the demonstrator (50 x 40 mm) on 

the Röders system, as well as the corresponding processing times 

(graphic: Röders/ Hufschmied) 

Bumble-Bi micro-tools from Hufschmied 

The machining of embossing tools for bipolar plates is a particular 

challenge for the milling tools. This is due to the hardness 

of the material to be machined and the long running 

time of the programs, sometimes well over 100 hours. And 

the required accuracy only allows for low wear. Hufschmied 

developed the special "Bumble-Bi" series of micro-tools for 

this purpose. These include high-feed milling cutters for 

roughing as well as torus milling cutters, ball nose end mills 

and flat ball end mills. The latter are a kind of hybrid between 

torus and ball end mills. All tools receive a specially developed 

PVD coating, whose extremely smooth layers ensure 

good temperature management. The milling tools used to 

manufacture the sample and their application parameters are 

summarized in the table. 

The demonstrator was 

milled in Hufschmied’s 

technical center on this 

five-axis Röders RXP 

501 DS; the system is 

equipped with the MHT 

medium distributor 


Application data of the Hufschmied tools 

used to machine the demonstrator 

(graphic: Hufschmied) 


35

processes 

removes the chips and their heat content from the milling 

cutter and the workpiece. The lubricating medium, consisting 

of carefully selected hydrocarbons, is supplied in extremely 

small quantities (2-10 ml/hour). This is nevertheless sufficient 

to optimally lubricate the cutting edges. During hard machining, 

the heat generated at the cutting edges is reduced 

by approx. 50 %. The main advantages are significantly 

longer tool lives, higher cutting performance of the machine 

and better workpiece surfaces. 

The hollow sleeve of the MHT media distributor encloses the tool 

holder without touching it or rotating with it; air and lubricant 

are supplied via the docking interface underneath the spindle 


Optimum lubrication with the 

MHT media distributor 

The right combination of cooling, lubrication and removal 

of chips from the work area plays a decisive role in machining 

processes. The MHT media distributor enables a particularly 

efficient and at the same time cost and energy saving 

approach. The core element is a conical sleeve that is permanently 

assigned to the tool holder and is exchanged with it 

when the tool is changed, but does not rotate with the milling 

cutter. It is docked underneath the spindle and supplied with 

compressed air and lubricant from there. 

Measurement technology and quality control 

The milling cutters used in this project have diameters down 

to 0.2 mm. For quality control very small and narrow contour 

areas, e.g. on the flanks of the flow channels and on the 

cutting edges of the forming/stamping tools, must be monitored. 

As this involves recognizing details down to a single 

µm, the measurement uncertainty of the measuring system 

used should normally be ten times better than the production 

tolerances to be checked. However only a few coordinate 

measuring machines are up to such requirements. 

In order to be able to record these measuring points with 

reasonable effort, a Zeiss DotScan optical sensor with a measuring 

rate of up to 1,000 measuring points/s was used, which 

was guided over the sample in three different angular positions 

using a rotary swivel unit. 

The main cooling and cleaning work is performed by compressed 

air ejected from nozzles arranged in a ring at the 

lower edge of the sleeve. This powerful air jet immediately 

The achieved quality of the component 

(graphic: Röders) 

Monitoring the demonstrator using the Zeiss DotScan 

optical sensor with an MPE of 1.8 µm + L/350; in order to be able 

to better measure the flanks, it was moved over the sample 

using a Zeiss “Contura” coordinate measuring machine 

with an RDS rotary swivelling unit 

(photo: Zeiss) 

Results 

The results presented here (scatter ± 3 µm) demonstrate the 

efficiency of the process chain described. With the right 

choice of components and a suitable procedure, a high level 

of process reliability can be achieved even when machining 

high-strength or hard tool steels. In addition high quality 

requirements can be met. It should be emphasized though 

that this requires the consideration of all aspects of a given 

process chain in detail. 

further information: 

www.hufschmied.net // www.mht-gmbh.de // 

www.roeders.de //www.openmind-tech.com // 

www.bohler.de // www.zeiss.de 



Planetary Lapping machine 

for PCD and CVD 

Coborn’s Planetary Lapping machines are designed to polish the 

top surface of PCD discs to a flat, mirror finish. They can also be 

used to polish CVD discs and PcBN. 

The machine consists of a number of independent work heads which hold the 

discs against a large, horizontally mounted planetary motion grinding wheel. 

It is impossible to use flood cooling when polishing large areas of PCD as the 

discs ‘aqua-plane’ on the wheel surface. Therefore the lapping is a dry process 

and the wheel is internally cooled using water from an associated water 

chiller. 

Chilled water is also fed to the back of each disc. This maintains the disc at 

a uniform temperature to minimize disc dishing. The PL5i is equipped with 

six work heads as standard. Each arm is fitted with a double gimbal fixture 

to allow the disc to self-level. The disc holders are motor-driven. The lapping 

pressure can be individually adjusted. 

The lapping or polishing of the top surface of PCD or CVD components is 

desirable to produce a smooth surface for chip flow and a good cutting edge 

for geometric integrity. It also maximizes edge life, enhancing the characteristics 

of PCD and also minimizes surface deviations over a large PCD or 

CVD area. 

The PL5i has a new, user-friendly touchscreen control system providing 

more clarity on display status and more detailed diagnostics. New features 

include spindle load monitoring and the planetary wear indicator. 

Planetary Scaife benches for single crystal diamond 

Coborn’s Planetary Scaife benches are generally used to polish facets on 

single crystal diamond tools. They may also be used in gem diamond polishing. 

The bench is available with a granite top, PS2BG or a steel top, PS2BS. 

The Planetary Scaife bench combines the high speed rotation of a scaife plate 

with a relatively slow, smooth, horizontal planetary motion. The planetary 

motion speed is variable between 0-50 cycles/minute. 

This motion gives a number of advantages over a standard scaife: 

the plate does not become tracked as polishing takes place over an 

annular band, the scaife surface remains smooth and flat 

the motion results in a constantly changing angle of attack: this gives a 

‘self-zooting’ action producing line-free facets without manual work 

in many situations the optional tang can be set on the machine and 

the diamond or tool left to polish 

‘knarted’ stones become easier to polish as the angle of attack 

constantly changes 

Coborn has developed the PB2 Portable Balancing System, which can be 

used in conjunction with the balance cap supplied on all PS2B benches. The 

PB2 is an optional extra and is utilized to fine-tune the balance of the scaife 

plate in-situ on the bench. This does not replace the need to pre-balance the 

plate before mounting, but can eliminate almost all vibration from the polishing 

system. 

PL-150, 

precision lapping of PCD and CVD discs 

TL1 – the dual-purpose table lapping 

and wheel preparation machine 

The TL1 is the latest addition to Coborn’s single 

crystal and natural diamond processing range 

of machinery. The TL1 is a dual-purpose machine 

that may be used to generate the final 

cutting edge on SCD tooling after processing 

on Coborn’s Planetary grinding machine 

ranges, or it can be used to prepare a grinding 

wheel before use. 

For producing high-quality SCD tools, new 

wheels need to be prepared correctly. This 

process can take up to three days and during 

that time the premium grinding machines 

will not be producing tools – or profit. The 

TL1 is a cost-effective solution to this problem. 

Wheels can be prepared while the precision 

machinery continues to produce tools 

uninterrupted. One TL1 can provide prepared 

wheels for many grinding machines. 

The second function of the TL1 is for table 

lapping to produce the final cutting edge 

either for new or repaired SCD tools. This 

process is a more hands-on operation but still 

releases the more expensive machinery to 

enable continued tool production. 

further information: www.coborn.com 


37


Together to success 

At the Polish plant of WHITE, the 

world’s leading manufacturer of orbital 

motors and steering solutions, an S110 

internal cylindrical grinding machine 

from STUDER has recently been contribut 

ing to efficient production. 

It is April when the truck sets off on its journey 

north from the STUDER plant in Biel, 

Switzerland, to a distance of around 1000 km. 

Its destination: the Polish production plant 

of WHITE in Wrocław, the world’s leading 

manufacturer of orbital motors and steering 

solutions. On board is a valuable cargo – the 

S110, a modern and high-precision internal 

cylindrical grinding machine. “It’s always a 

great moment when a new machine is delivered”, 

says Paweł Soćko, senior process engineer 

at WHITE after the arrival in Wrocław. 

STUDER S110 internal cylindrical grinding machine 

“We opted for the S110 because it exactly 

meets our high requirements in terms of performance 

and quality in production. Thanks 

to the cooperation with STUDER we can 

grind our components with the highest precision 

and comparatively low costs – they therefore 

contribute to our success”, he explains. In 

the modern plant with around 600 employees, 

several STUDER machines are in use, as well 

as other machines from sister companies of 

the UNITED GRINDING Group. They enable 

the production of innovative electrohydraulic 

high-performance solutions, for example for 

steering systems in agricultural and construction 

machinery. WHITE has over 50 years of 

experience in this field and is now part of the 

internationally established Interpump Group. 

Customers benefit from optimization 

“The relationship with WHITE has existed for decades and we are delighted 

that our grinding machines can continuously contribute to their success 

there”, says Adrian Schürch, area sales manager for Poland at STUDER. As 

STUDER has a local representative in Poland, communication went very 

well right from the start. However, before deciding on a specific machine 

model, the requirements of the component to be produced with it had to be 

determined. “As always, we examined this in detail with our specialist team 

to find the optimum solution for the customer”, reports Schürch. 

Adrian Schürch, area sales manager Poland 

Automation solution on the S110 



competence center in Biel. “The optimization is based on the specifications, 

where all technical specifications, the geometry of the component to be manu - 

factured and operation plans are defined”, he explains. His team worked 

closely with the specialists from WHITE. “We were very impressed by their 

technical expertise, professionalism and constructive attitude. It was a very 

pleasant cooperation, and we found the perfect solution between customer 

requirements and technical implementation”, emphasizes Mastroianni. 

One of the challenges was to find the best mix of short cycle times in 

series production and high component quality. Thanks to the optimization, 

the S110 can grind around 350,000 high-quality sleeves per year at the plant 

in Wrocław. WHITE is also satisfied with the result: “We produce in high 

volume, and this requires the best solutions in the world – because we cannot 

afford any losses due to insufficient precision or fluctuating capacity”, 

emphasizes Paweł Soćko and adds: “The STUDER S110 meets our requirements 

perfectly, it is stable and reliable.” 

OSPM – a compact steering unit suitable for 

vehicles and mobile machines with 

high axle loads 

Specifically it is about the internal grinding 

of hardened steel sleeves for hydraulic steering 

systems. It quickly became clear that the 

S110 from STUDER’s wide range of models 

was ideal for the component geometry and 

production requirements. “In addition to high 

precision, reliability and compactness, this 

internal cylindrical grinding machine also 

offers an excellent price-performance ratio”, 

says Schürch. But that was just the beginning. 

The companies team specially configured 

and adapted the S110 for WHITE so that the 

machine could be optimally integrated into 

the production process. 

Perfect combination of 

short cycle times and high quality 

This process fell within the remit of Cesare 

Mastroianni, who is responsible for project 

management at STUDER’s internal grinding 

The S110 at a glance: 

• compact and flexible internal cylindrical 

grinding machine for processing 

medium-sized workpieces 

• center height of 102 mm (4”) and 

a maximum grinding length of 

120 mm (4.72”) 

• optional loader for loading and 

unloading 

• up to three grinding spindles in a 

linear arrangement enable external 

and internal grinding in just 

one clamping operation 

• the StuderSIM and StuderWIN operating 

systems enable safe programming of all 

basic cycles for grinding, dressing and 

process-supporting measurement 

Automation ensures more efficient production 

Soćko cites yet another reason for choosing the S110: its automation capability. 

In the optional loading and unloading cell, a robot picks up the raw 

parts from a pallet, clamps them in the machine, and places the finished 

ground sleeves in another pallet. This process only takes a few seconds per 

sleeve. The S110 can therefore operate autonomously for at least an hour 

without human intervention and internal functions facilitate quality control. 

“In practice we even have almost two hours of autonomy, which reduces 

labor costs enormously”, reports Soćko. This also has major benefits for 

production efficiency: the employees can devote themselves to other tasks 

and the robot ensures a speed and consistency that would otherwise not 

be possible. 

Overhaul gives a second life to aging machines 

While the new S110 improves production with its high-tech capabilities, 

WHITE continues to rely on tried and tested technology. “The oldest of our 

eight STUDER machines is still working well after 30 years”, emphasizes 

Soćko. One reason for this is the machine overhaul service that the company 

offers its customers. With this service an aging machine is restored to 

as-new condition as when it was delivered. Steven Thiel, STUDER Customer 

Care Consultant for Eastern Europe and Northern Germany, explains the 

benefits: “Customers who are familiar with their machines and do not 

require new technologies for grinding components benefit enormously from 

this. This is because the machine overhaul only costs a fraction of the price 

of a new system and the customer can continue to work with the familiar 

machine in as-new precision and quality.” 

The ecological factor is also important for WHITE, which has 

already taken advantage of several machine overhauls. “Environmental 

aspects always play a role for us, which is why STUDER machines with their 

energy-saving solutions fit in with our corporate values”, explains Soćko. 

This is because instead of replacing an outdated model that once required 

a lot of energy and resources to build, it can be used again for decades. It 

takes around three months to overhaul a machine in Thun, Switzerland, 

with STUDER taking care of all aspects of logistics. “During this time, we 

provide a loan machine so that there are no production downtimes”, says 

Thiel, who is available to WHITE as a daily contact. Proven processes combined 

with the latest technology: WHITE believes it is well-positioned for 

the future. “Properly implemented processes ensure success”, says Soćko, 

adding: “STUDER has shown that they are the ideal company to accompany 

us on this journey.” 

further information: www.studer.com 


39


Successful conversion of production 

E-mobility is taking hold around the world – and 

the automotive industry is changing. Many manufacturers 

are shifting from internal combustion engines 

to electric powertrains. The Ford Motor Company – a 

long-term partner of Liebherr-Verzahntechnik GmbH – 

will be making most of the electric drive units for its 

European production at its UK transmission plant at 

Halewood near Liverpool. 

As before, Ford will be using Liebherr gantry technology, but 

for electric drive units rather than transmissions for internal 

combustion engines. 

The world’s sixth-largest car manufacturer aims to “electrify” 

its portfolio in Europe. The switch to producing electrical 

components in Halewood plays a crucial part in this. At this 

plant, Ford has invested for the first time in Europe in the 

production of components for all-electric vehicles, producing 

power units consisting of an electric motor and a singlespeed 

transmission. 420,000 units will come off the production 

line annually instead of the previous 250,000 units, 

enough for 70 % of the 600,000 electric vehicles Ford plans to 

sell in Europe each year. 

There are two reasons why Halewood was chosen. Firstly, 

it has enough space to expand production, and secondly, it 

is very close to the Liverpool city region Freeport. This is a 

special economic zone created following Brexit, which offers 

special economic regulations, as well as customs and tax 

incentives. 

Using existing technology differently 

Ford and Liebherr have been working together for 30 years, 

implementing numerous projects including retooling projects. 

However this was the first one to involve moving existing 

equipment to another location. “We took equipment from 

lines that were no longer producing internal combustion 

engines from Dagenham to Halewood, then upgraded and 

modernized them”, reports project manager Steve Treweek, 

senior process engineer at Ford Motor Company. “This saved 

us a lot of money – buying the lines brand new would have 

cost an additional 30 to 40 million Euro.” The converted 

equipment was built in 2010 and is thus still relatively new. 

Retooling it is cost-effective and the result is production lines 

that look – and run – like new. The plant is still in the rampup 

phase and production is scheduled to start October 2024. 

Gantry technology and e-mobility 

“If the project shows one thing, it’s that gantry technology is 

alive and well”, says Roman Buhmann, key account manager 

and Liebherr’s project manager for Halewood. “Anyone who 

thinks that gantry systems will die out along with combustion 

engines has got it wrong. Gantry technology is still 

needed – for producing gearboxes for electric drives just as 

much as for traditional engine blocks.” 

The friction roller outfeed conveyor for 

unloading the reject parts 

Liebherr gantry technology 

for the entire material flow 

The converted plant uses four lines to produce electric motor 

housings, gearboxes and covers and for assembling the transmission. 

Liebherr technology plays a leading role everywhere, 

including gantry robots for tooling the CNC machines (LP 

200), gripper systems, connecting belts between gantry lines 

and maintenance areas, a tower storage system, state-of-theart 

part tracking and SPC stations for removing workpieces 

for quality assurance. 

“Liebherr technology handles the entire material flow of 

transport, temporary storage, control and tracking – including 

process reliability, material flow optimization to guarantee 

cycle times on the production lines, as well as removal 

and data evaluation”, says Uwe Radigk, Powertrain Manufacturing 

sales manager at Liebherr-Verzahntechnik GmbH. 

“Only the control technology is completely new; 90 % of the 

hardware is re-used and upgraded. The energy supply chains 

have also been retrofitted, and the safety systems have been 

brought up to date to ensure the maximum possible occupational 

safety.” 

Productivity, quality and flexibility 

The new plant offers a significant increase in productivity: 

availability will increase from 80 % to 87.5 % in the first step 

and up to 90 % in the future. In terms of the gantry technology 

alone, it is no less than 98 %. “The advantages of Liebherr 

gantry technology are clearly productivity, quality and flexibility 

in equipment and engineering – and also tidiness”, says 

Steve Treweek. “Looking around the factory, you can’t tell 

that it’s used equipment. Everything looks brand new.” 

Challenges during the conversion 

The change from producing heavy cast iron parts for diesel 

engines in commercial vehicles to the much lighter, more 



deli cate parts for electric powertrains was one of the key 

characteristics of the project. The engine block for which the 

lines were originally designed weighed 120 kg, while the new 

electric motor block is about the same size, but is made of 

aluminum and weighs only 13 kg. This meant all the axes and 

grippers of the gantry robots had to be replaced. 

Another particular challenge was adapting the equipment 

to the low roof height in Halewood. The halls there are only 

5.2 m high, while the standard height of Ford production 

halls is 6.4 m. Liebherr specially converted the entire gantry 

system for the 1.2 m lower height. 

The IT system was also changed: part tracking no longer 

takes place by reading data tags but using a cloud system. 

This means Liebherr not only moves the parts but also transfers 

the associated data. 

On top of this, it was all done in a very short time, made 

more difficult by the coronavirus pandemic. Normally a 

timeframe of 18 to 24 months is estimated for installing a 

new gantry system – without transferring all the equipment. 

This time, though, it only took eight months from the installation 

of the first beam to the initial test runs in production. 

Seamless collaboration 

Steve Treweek knew from the start that he would carry out 

this project with Liebherr. The decisive factors being not only 

the quality of the equipment, but also the know-how, comprehensive 

expertise in Ford projects and the reliability of the 

companies engineering team. “Over the last 15 years I have 

had all my gantry technology supplied by Liebherr”, he says. 

“I’m very experienced and know exactly what I need – but even 

with less experienced Ford project managers, the Liebherr 

team would have mastered the task. I know what the teams, 

assembly crews and project managers can do. When it comes 

to the whole system, there’s no one comparable.” 

The excellent collaboration between the two teams was 

crucial in ensuring that the Halewood project ran smoothly 

despite all the challenges. “This kind of thing is only possible 

with Liebherr”, Steve Treweek emphasizes. “We have a deep 

mutual understanding and both teams complement each other 

perfectly. I would always argue for Liebherr as a supplier. 

As a Ford project manager I need quality, reliable project 

partners and a good team on my side – and this is exactly 

what they give me. It’s a pleasure to work with Liebherr." 

information: www.liebherr.com 

England receives its first arc80X 

At the beginning of the year, GEFERTEC introduced 

its new generation of the arc80X with an 

assembly space of up to 8 m 3 to allow additive manufacturing 

of very large metal parts. Kingsbury has now 

purchased the first new generation machine for the 

application center at its subsidiary, Additure. 

Kingsbury and GEFERTEC have enjoyed a close partnership 

over the past five years, with the English company acting as 

the exclusive distributor for GEFERTEC’s arc machines on 

the British market. Approximately two years ago, Kingsbury 

founded its subsidiary Additure, which focuses exclusively 

on additive manufacturing methods. Because potential 

customers for additive manufacturing need a great deal of 

advice and support, Additure operates an application center 

in its Preston location. This center is equipped for contract 

manufacturing and can also be used to perform feasibility 

studies. An arc405 is already in operation here. The contract 

for purchase of the new arc80X was signed in April, with 

delivery of the machine scheduled for early 2025. 

Demand for larger parts 

Wire Arc Additive Manufacturing (WAAM) is particularly 

well suited for the creation of large parts. The arc machines 

produced by GEFERTEC are complete manufacturing systems 

based on the WAAM process. Traditional metal inert 

gas welding is used for the additive manufacture of parts, creating 

a near-net-shape part layer by layer. The arc machines 

combine this process with the standard NX software from 

Siemens and a Sinumerik control architecture. GEFERTEC 

GEFERTEC is 

delivering the 

first machine 

from the new 

arc80X series 

to its longtime 

partner 

Kingsbury in 

the UK 

offers specially developed CAM software for individual production 

requirements. The resulting process offers high build 

rates, and because wire is used as the raw material, handling 

is easy and the material is cost-effective. 

Having observed the growing need for larger parts, 

Kingsbury decided to invest in a new arc80X, which can 

manufacture parts weighing up to eight tons depending upon 

the respective design. The assembly space for the 3-axis version 

is 2 x 2 x 2 m, and the 5-axis version can print parts with 

a diameter of up to 0.9 m and a height of up to 1.4 m. This 

new generation of machines also offers a very high degree of 

automation to increase manufacturing efficiency. Automated 

functions include integrated tool measurement, gas nozzle 

cleaning, wire cutting and replacement of wear parts. 

information: www.gefertec.de 


41


Automation of the UMILL 630 with 

EROWA Robot Compact 80 

EMCO was pleased to announce the possibility to 

automate the UMILL 630 vertical milling machine 

with the EROWA Robot Compact 80 (ERC80) pallet 

changing system at AMB in Stuttgart 2024. Already 

renowned for its precision and reliability in 5-axis 

simultaneous machining, the UMILL 630 can now be 

further enhanced through integration with EROWA’s 

advanced automation systems. 

The UMILL 630 is a universal milling machine for 5-axis 

simultaneous machining, which is characterized by a clamping 

range of 630 x 500 mm and a robust machine structure 

made of cast iron and welded steel, which guarantees maximum 

stability and thermal symmetry. 

Example of a magazine 

configuration 

Supported by 45 mm 

roller guides on the X- 

and Y-axes and direct 

drives in all linear axes, 

the large traverse paths 

of 500 mm in X, 460 mm 

in Y and 450 mm in Z of 

the UMILL 630 enable 

the production of workpieces 

with a maximum 

diameter of 600 x 400 mm 

in a wide range of batch 

sizes. Another positive 

feature is the high rigidity, 

which stands for optimum 

precision and excellent 

surface quality 

on the workpiece. All 

axes are equipped with 

a direct measuring systems 

to achieve perfect 

results. 

Thanks to the front support for the included table as standard, 

workpieces weighing up to 300 kg can be machined 

without compromising performance. The water-cooled 

motor ized spindle with a maximum speed of 15,000 rpm 

ensures high performance and optimum precision. 

Despite the generous traverse paths, the machine design 

is compact and ergonomic. Complex machining processes 

can be carried out easily and efficiently with the 30-position 

tool magazine which can be extended to 60 or 90 tool positions, 

other magazine sizes on request. The motor ized spindle 

can be designed with HSK-63A or ISO40 holders. The large 

machine door makes it easy to load the machine. As an option, 

an automatic door can be fitted on the right-hand side 

for the integration of intelligent automation systems, such as 

the solution presented at the AMB trade fair in Stuttgart. 

Universal milling center for 5-axis simultaneous machining 

and Erowa Robot Compact 80 (rendering) 

Features and benefits of automation with ERC80 

One example is the combination of the UMILL 630 with the 

EROWA Robot Compact 80 (ERC 80), offering the optimum 

ratio between a large number of magazine positions and a 

small footprint, increased productivity and improved operational 

efficiency. With the ERC80 pallet changing system, 

the possibilities of the UMILL 630 can be fully utilized. With 

a transfer weight of up to 80 kg, the ERC80 can serve one or 

two processing machines, offering flexibility and competitiveness 

without compromising on quality. 

The ERC80 combines perfectly with the UMILL 630 to 

make the best use of the available space. It is ideal for production 

environments where space is a critical factor. The ERC80 

has features that ensure accurate and reliable parts handling, 

optimizing cycle times and reducing downtime. 

By integrating the UMILL 630 with the EROWA Robot 

Compact 80, EMCO offers a complete solution to optimize 

production processes. The automated loading and unloading 

system increases productivity, improves flexibility and 

reduces operating costs, while ensuring high quality of the 

machined parts. 

The machines are developed and produced entirely in 

Central Europe for fulfilling the highest requirements in 

terms of quality, productivity and efficiency. 

The UMILL 630 is the ideal vertical milling center for 5-axis 

simultaneous machining of demanding workpieces, whether 

in small or large quantities, with high demands on accuracy 

and surface quality. Integration with a pallet changing system 

enables high-precision and productive machining, even 

in unmanned shift operation. It is particularly suitable for 

tool & mould making, contract manufacturers, industrial 

companies such as automotive suppliers, general mechanical 

production and advanced training facilities. 

information: www.emco-world.com 


New standards with world premieres 


GF Machining Solutions made a strong impression 

at this year’s AMB with the presentation of groundbreaking 

innovations. Highlights included the world 

premiere of the MILL S 400 U with Sinumerik One, 

which combines HSC Milling with Siemens technology, 

and the European premiere of the Laser S 500 (U), 

which opens new possibilities in the micromachining 

of 3D molds. 

Visitors were also able to experience other top products 

such as the MILL S 600 U with grinding function and the 

CUT X 500 with cobot automation, a benchmark in wirecutting 

EDM. 

World premiere of a milling machine 

with Siemens control 

The MILL S 400 U has been equipped with a Siemens 

control system – a unique feature for HSC milling machines. 

This further development demonstrates the constant endeavor 

to combine state-of-the-art technology with superior userfriendliness. 

At the booth the MILL S 600 U G showcased 

the combination of milling and grinding technology with 

extremely high machine dynamics and consistent thermal 

stability results in high-quality products, which helps customers 

to achieve a quick return on their investment. This 

feature provides a seamless transition between processes 

avoiding the need to reclamp the part, with reduction in 

idle and waiting times, whereas the main benefit is increased 

accuracy. The MILL S/X (U) is the ideal machine, especially 

for applications that require high surface quality. 

Tiltable and adjustable dressing spindles close to the 

working area on the MILL S and MILL X ensure a 

fast-sanding set-up and process 

The My rConnect platform offers a complete digital overview 

and fast connections to service 

European premiere of the LASER S 500 (U) 

combining all the know-how in one machine 

Accuracy and speed are at the heart of the brand-new LASER 

S 500 (U), shown at the exhibition. With its outstanding 

capa bilities and performance in processing a wide range of 

soft and hard materials, it sets the course for the future of 

micromachining and 3D surface processing. Manufacturers 

in the information and communication technology, medical 

technology and watchmaking sectors can look forward to 

more effective and efficient machining technology. 

Pioneers of electric discharge machining 

display their skills 

The latest CUT X series combines more than 70 years of EDM 

history in the best wire-cutting EDM machine ever built. 

There is no compromise between precision, surface quality 

or speed: the unique technologies of a CUT X ensure the 

best results in all three areas. The CUT X is characterized by 

perfect axis accuracy and a thermal management system that 

ensures constant precision under all operating conditions. 

The well-known Intelligent Power Generator with Direct 

Power Supply (IPG-DPS) and the unique twin-wire technology 

make the impossible possible at unbeatable speed. 

My rConnect – the new platform with 

direct service access, digital and without detours 

“My rConnect” offers users a seamless way to reach their 

service contacts with a single click, eliminating the need for 

hotlines or waiting in queues. This digital portal provides 

access to the ticket system, facilitates communication 

through chat and video calls, and allows easy monitoring of 

machine status on the go. Users can also receive push notifications 

on their phones, enabling proactive problem identification 

and resolution before production is impacted. This is 

just the beginning, as more functionalities and features are 

set to be added soon. 

information: www.gfms.com 


43


Simple and secure networking 

The UNITED GRINDING Group’s customers are 

as diverse as the group itself. They range from small 

businesses to large corporations, from single to mass 

production, and from the automotive industry to aerospace, 

tool and die, and precision mechanics. For the 

manufacturing of complex and sophisticated parts, 

not only the Group’s grinding, eroding, or measuring 

machines are used, but also other technologies and 

therefore machines from third-party manufacturers, 

such as milling machines or lathes. 

Aggregating valuable data from this heterogeneous machine 

park to optimize production can be cumbersome and timeconsuming. 

However this has been made easy with umati 

(universal machine technology interface), which has become 

the global interface standard for machine tools. 

The simple networking of various machines from different 

manufacturers and ages was demonstrated in production 

at STUDER, the Group’s cylindrical grinding machine 

specialist. In addition to these grinding machines, machine 

tools from DMG Mori and WALDRICH COBURG were networked 

using umati. The data was then merged into the production 

monitor of UNITED GRINDING Digital Solutions. 

The interlinking has shown that umati can not only be used 

for new machines, but also older existing machines can be 

networked without any problems. 

The WALDRICH COBURG machine has been in production 

at STUDER for over a decade and is predestined for this 

project. An exciting project for an apprentice, Christian Josi, 

head of digital engineering at the Group, thought. He immediately 

received support from Marc Baumgartner, who is responsible 

for training automation technician apprentices at 

STUDER. Christian Breitenbaumer (4 th -year automation 

technician apprentice at STUDER) then took on the task, analyzed 

the structure, functionality, and electrical diagram of 

the WALDRICH machine, and provided support in evaluating 

a suitable, umati-compatible and cost-effective IoT device 

for interface communication. This was wired and parameterized 

by him. Integration into the production monitor was 

then just a formality – thanks to umati. The key productivity 

figures of the WALDRICH machine, together with the data 

from the other production systems at STUDER, can now be 

displayed in real-time on the shop floor dashboard, the PC, or 

on a smartphone using the Digital Solutions mobile app. 

information: www.grinding.ch 

Compact solution for high-end machining 

For DN Solutions, AMB 2024 in Stuttgart was 

all about transformation. The global manufacturer 

of CNC machine tools unveiled its new DNX 2100S 

machining center to the public for the first time. 

With the DNX 2100S, DN Solutions launches a new high-end 

turn-mill center, whose flexibility bridges the gap between universal 

lathes and turn-mill machines. Through the 4+1-axis 

machine, DN Solutions aims to target companies that have 

not yet transitioned from universal turret lathes to high-end 

turn-mill machines. Many metalworking companies, for 

instance, still rely on inflexible turret machines due to cost 

considerations. The CNC machine tool expert seeks to partner 

with these customers and assist them in developing and 

transforming their machines. 

Process reliability through complete machining 

The main difference between the DNX and a turret machine 

is its increased flexibility. By integrating turning, milling 

and measuring functions, the machining center can fully 

process a part from all sides with fewer tools and in a single 

setup – no additional machines are required. This capability 

is enabled by the flexible 12,000 rpm turning/milling spindle, 

which can machine the part from all sides with an indexing 

accuracy of 0.0001 mm, often utilizing simple standard tools. 

In contrast universal turret machines typically rely on costly 

tooling solutions, and the workpiece often needs to be manually 

re-clamped to machine the second side. This method not 

only occupies a significant portion of the 12 tool positions on 

the turret but also increases setup time – and therefore machine 

downtime. Additionally the DNX’s chain magazine, 

which can hold up to 60 tools, along with the ability to set up 

during machining, provides a clear advantage. The combination 

of complete machining of individual parts in one single 

setup and in-process measurement increases process stability 

significantly, which is essential for machine automation. 

information: www.dncompany.com 


A new ball pin leaves the machine 

every seven seconds 


Whether in the steering system or in the chassis – 

ball joints are indispensable in our cars. They not only 

act as a kind of pivot point between different elements, 

but are also usually in constant motion and exposed to 

high physical loads. In this context, ball pins and ball 

sleeves are among the safety-critical car components 

that must leave production with a high surface quality 

and micrometer precision without exception – despite 

high quantities and general cost pressure. How 

can this task be implemented particularly efficiently 

and with minimal chip-to-chip times? EMAG now has 

the answer with a new machine: using the VST 50, a finished 

ball pin leaves the machine every seven seconds 

with each component undergoing an exceptionally 

comprehensive measurement. 

A new task for the turning specialists from southern 

Germany – until now ball pins were not a typical automotive 

component that passed through an EMAG machine. So how 

did this design and development come about? “It has to be 

said that the task sounds very much like EMAG in many 

respects. It involves large quantities, special surface requirements 

and low unit production costs. We repeatedly ensure 

these qualities for various components”, explains project 

manager and development engineer Frank Haas from 

EMAG. “In this respect it was obvious that a major customer 

approached us with this task some time ago. The main question 

was whether we could exceed the performance values of 

existing machines in ball pin production. This was the starting 

point for the development of the VST 50.” 

The result has now been available for some time and a 

simple look at this machine makes it clear: the designers 

have done a particularly good job here. On the one hand the 

VST 50 has highly automated processes, including the use of 

three robots. On the other hand it is easy to operate using the 

EDNA apps, which also include various measurements and 

the robots. For the actual turning of the ball and neck of the 

ball pin (only these areas are involved here), there are two 

suspended workpiece spindles that can be moved irrespective 

of each other. As a result one spindle is always loaded 

and unloaded while the other is in use during the machining 

process. The associated tool compound slides are split in two: 

the tools on the left-hand side are mounted on a rotary B-axis, 

which enables the ball to be turned and smoothed with precision. 

In addition, the ball diameter and shape can be adjusted 

using a linear U-axis. Special tools for neck machining are 

mounted on the right-hand side. 

High-productivity loading 

Loading and unloading are in turn carried out by the three 

robots, which are arranged in parallel in front of the machine. 

Each is responsible for a different sub-process: the left-hand 

robot handles the workpiece between the transfer station and 

the first workpiece spindle. The middle robot performs the 

The tools for 

machining the neck 

are on the righthand 

side of the 

compound slides 

and those for 

machining the ball 

are on the left-hand 

same task on the second workpiece spindle, while the right 

robot handles the workpiece between the transfer station and 

the outer automation assemblies. But why not use a robot that 

performs these three tasks alternately at this point? “That 

would certainly be possible”, confirms Haas. “However we 

wouldn’t be able to achieve the extremely short cycle times. 

The various movements are sometimes carried out simultaneously. 

Our solution ensures that a finished workpiece 

leaves the machine every seven seconds and the chip-to-chip 

time is less than two seconds.” 

Rapid speed and precision – this also explains why the robots 

mentioned are also used for tool changes, whereby EMAG 

has divided the entire process into two parts, so to speak. 

On the one hand, there is the operator’s task: he always sees 

a prediction for the tool change on the central control panel. 

If he wants to change a tool he simply presses a button and 

the tool magazine swivels outwards for the change. It is important 

to note that the production process is not interrupted 

during this process. After the exchange, the magazine swivels 

back to its starting position. The manual process is now complete 

and an automated process follows in the second step. 

For this the left-hand robot first puts down its workpiece 

gripper and picks up a tool gripper. It then removes the worn 

tool from the interior of the machine and replaces it with a 

new one, taking it from the magazine. To further increase 

process capa bility, each tool is coded with an RFID chip so 

that the tool data can be transferred accordingly. The entire 

tool change takes less than 90 s. 

Light band micrometer provides 

many measured values 

Finally, there is the issue of process reliability as a key economic 

factor for a component that must leave production 

without any error tolerance. EMAG relies here on a 100 % 

solution: each component passes through a light-band 

micrometer, which determines the required measured 

values in fractions of a second with a comprehensive result. 

The final ball and neck diameter is determined and any chips 

are detected at the same time. In addition, a high-resolution 

process camera is located directly in front of the loading 

hatches. Its live image appears on the panel at the touch of a 

button. The operator can easily check whether, for example, 

the chip formation is causing a fault in the process. 

further information: www.emag.com 


45

components 

Modular systems for cable carrier systems 

TSUBAKI KABELSCHLEPP places a focus on its 

TOTALTRAX solutions at SPS 2024 in Nuremberg. 

The pre-assembled cable carrier systems, ready to 

install, help users to increase productivity, while also 

improving the predictability of their processes and 

creating cost transparency and reliable quality. 

“In the current volatile economic situation, medium-sized 

companies face various challenges such as uncertainties in 

the supply chain, rising costs and high competitive pressure”, 

explains Jochen Becker, sales director D/A/CH at TSUBAKI 

KABELSCHLEPP. “Complete systems are an advantage in 

this situation, as they improve the predictability of processes 

and costs while minimizing the risk of downtime caused by 

delivery bottlenecks or incorrect assembly. With our tailormade 

TOTALTRAX systems we additionally offer customers 

long-standing experience, assured quality and flexibility in 

the event of fluctuating demand.” 

TOTALTRAX systems are available from simple to complex, 

from one-off custom items to large production runs, 

with and without connectors, sheet-metal and 

add-on components, as single-axis or multi-axis systems 

Predictability, cost transparency and reliable quality: 

the pre-assembled TOTALTRAX cable carrier systems 

help users focussing on their core skills 

Not only the mechanical and plant engineering sector 

benefits from the TOTALTRAX system. Because ten years 

ago, customers came mainly from the mechanical engineering 

industry, TSUBAKI KABELSCHLEPP has now considerably 

expanded the scope of application for its system concept. 

Today TOTALTRAX can be found in port cranes and automatic 

milking systems, for example, as well as in a range of 

other applications. 

Extensive range of modular systems 

without material dogma 

When configuring the customized TOTALTRAX systems, 

the company always considers all its cable carrier ranges 

and components. This provides an extensive modular system 

that can be used to generate an optimum solution for virtually 

any requirement. A special advantage: the options also 

apply to the available materials. Steel, plastic or hybrid carriers 

can be used, depending on the application and the local 

conditions. Hybrid carriers combine plastic sidebands with 

alu minum profiles and can cover any required width in millimeter 

increments. 

“Compared to our competitors we can fall back on one of the 

broadest portfolios in the industry”, explains Jochen Becker. 

“That gives us the option of offering a large number of size 

and width variants – all without any material dogma. Customers 

can find everything in our range from small plastic 

cable carriers to XXL steel cable carriers. Our TOTALTRAX 

systems are available from simple to complex, from one-off 

custom items to large production runs, with and without 

connectors, sheet-metal panels and add-on components, as 

single-axis or multi-axis systems. Anything is possible.” 

Expert coaching from start to finish 

The engineers and specialists from the company ensure 

that the right solution from the vast number of options is 

produced every time. They have many years of experience in 

the field of cable carriers and are also well versed in mechanical 

and plant engineering. This means that each project 

receives competent support, from the initial inquiry to the 

installation of the TOTALTRAX system. 

further information: www.tsubaki-kabelschlepp.com 


components 

On the fast track 

Mobile robots reduce costs for SMEs 

Mobile robotic systems are being used in more 

and more work areas, from e-commerce warehouses 

to modern restaurants. Conventional models on the 

market start at around € 25,000, while solutions with 

an integrated robot arm are priced at approx. € 70,000 

(prices may vary, depending on the country). 

However, widespread use is often unaffordable for small and 

medium-sized companies due to the high prices. igus wants 

to change this with new low-cost robotics offerings and is 

presenting a series of low-cost mobile plastic robots at the 

Hannover Messe. 

The market for automated guided vehicles (AGV) and 

autonomous mobile robots (AMR) is booming: the global 

market for mobile robotics, including service robotics, 

currently totals around $ 20.3 billion, and experts expect this 

figure to almost double by 2028*. Mobile robots are particularly 

widespread in material handling and industrial applications. 

And these smart helpers are even increasingly making 

their rounds in catering and hospitals. The plastics experts 

at motion plastics specialist igus have also been successfully 

testing AGVs in-house for four years – driverless shelves 

that deliver mail and shipments to offices as well as mobile 

robots in production that move transports and rotary stacking 

containers. The experience gained flows directly into the 

development of a new Low Cost Automation product line, 

the “ReBeL on wheels”. The goal: to pave the way for small 

and medium-sized enterprises (SMEs) to cost-effective 

mobile robotics. 

* German Robotics Association: 

“Autonome Mobile Roboter (AMR) –Was sind AMR, 

Aktuelle Zahlen, Hersteller”, March 2024 

Mobile ReBeL solutions for 

education, logistics and service 

The foundation of any mobile robotic system is the ReBeL. 

Using plastic makes the robot particularly affordable at 

€ 4,970 and, with a net weight of 8.2 kg, the lightest service 

robot with cobot function in its class (prices may vary). Without 

exception, igus develops and manufactures all mechanical 

components that make up the ReBeL. 

Its payload amounts to 2 kg and it has a reach of 664 mm. 

Various moving systems are planned in which the ReBeL is 

centrally integrated: igus is launching an affordable version 

for the education sector for € 14,699 – including the robot 

arm (prices may vary). Based on open-source software and 

equipped with a gripper, the ReBeL EduMove serves as an 

autonomous learning platform for educational institutions. 

It has a modular design, so that other functions can be 

added, such as lidar, camera technology or a slam algorithm. 

Another version is an automated guided vehicle for SMEs, 

igus launches a new series of cost-effective mobile AGVs 

(automated guided vehicles) and AMRs (autonomous mobile 

robots) for education, logistics and service with the aim of 

making mobile robotic systems affordable for SMEs 

(small and medium-sized enterprises) 

which can transport up to 30 kg. With the optional ReBeL, 

simple A to B positioning tasks can be carried out. It dispenses 

with expensive sensor technology and instead relies on 3D 

sensor technology developed in-house. Its price is € 17,999 

(prices may vary). The ReBeL Butler is best for simple but 

time-consuming pick-up and delivery services, for example 

in the hotel and catering industry. 

A lighthouse project on wheels 

The goal of all these developments is the lighthouse project, 

a mobile robot with integrated HMI and vision that would 

even be able to tidy up an office on its own. “With this project 

we are pursuing a bottom-to-top strategy in which certain 

components such as safety laser scanners are not included 

in the basic package so as to keep the price low”, explains 

Alexander Mühlens, vice president and head of the Low Cost 

Automation Business Unit at igus. 

“Nevertheless, the solution can be retrofitted for industrial 

requirements.” igus wants to present an affordable gripper 

with a large stroke and travel that offers a high degree of 

flexibility when gripping different geometries, among other 

things. Says Mühlens: “The areas of application for this 

planned low-cost AMR are extremely diverse and go far 

beyond simple transport tasks. They cover a huge range of 

use cases in different areas of life, such as cleaning tasks or 

serving coffee directly at the workplace.” 

further information: www.igus.de 


47

components 

New AI solution launched to accelerate 

the CNC machining estimating process 

CloudNC – a manufacturing technology 

company – announces the launch of 

CAM Assist Cycle Time Estimator, a new 

tool that accelerates the CNC machining 

estimation process and eliminates bottlenecks 

in the quoting workflow. 

Estimating and quoting for machining work 

is a manual, time-consuming and labor-intensive 

task for any machine shop. By automating 

this process for multiple parts simultaneously, 

Cycle Time Estimator allows users to turn 

around estimates up to twenty times faster, 

depending on the complexity of the part. 

As a result, estimators using CloudNC’s 

CAM Assist solution within Mastercam 

or Autodesk Fusion can generate accurate 

machining times and tool path strategies in 

bulk for 3-axis and 3+2-axis parts in minutes. 

They can then export that data seamlessly 

and integrate it with their estimation workflow, 

enabling them to quote for and win 

more work, while using their resources more 

efficiently. 

Theo Saville, chief executive and co-founder 

at CloudNC, said: “Estimating and quoting 

for new work is one of the biggest bottlenecks 

in machining, not only because it’s an expertlevel 

task that’s critical for winning new business, 

but also a huge time suck. Our solution 

accelerates that process while also allowing 

users to execute it on many parts at once, 

CAM Assist Cycle Time Estimator, a 

new solution from CloudNC, uses AI 

to accelerate how quickly machinists can 

estimate new work will take – 

a bottleneck in any machine shop 

By automating the estimation process for 

multiple parts simultaneously, Cycle Time 

Estimator allows CAM Assist users to turn 

around estimates for 3+2-axis parts 

up to twenty times faster 

That advance helps machine shops 

quote for and win more work, while 

using their resources more efficiently 

At the AMB diverse approaches of automated machine loading from 

simple entry to high-end solutions was shown 

turning around accurate estimates much faster than is manually possible, 

even for a genius-level estimator. Its capacity is far beyond existing estimation 

alternatives, and it’s a step change for any machine shop that regularly 

looks to pull in new projects or win new clients.” 

The Cycle Time Estimator is a new feature for CloudNC’s CAM Assist AI 

solution, which accelerates CAM programming. By using CAM Assist’s 

machining algorithms and tool selection to carry out estimates, Cycle Time 

Estimator reduces human inconsistencies in the estimating process, improving 

and standardising quote accuracy. 

The solution also provides meta-data for each part, including part volume, 

stock volume and other relevant data such as machining efficiency and 

number of operations, enabling the estimates to be easily integrated into 

existing workflows. 

Mark Hyde of FJH Group, a CAM assist user, said: “CAM Assist significantly 

reduces the time needed to generate tool paths and accurate cycle 

times, cutting our quoting time by about 70 %. It allows us to generate accurate 

cycle times and tool paths, ensuring we don’t over-quote or under-quote. 

This capability has helped us win more work by demonstrating shorter and 

more accurate cycle times.” 

The Cycle Time Estimator is available as a feature for CloudNC’s CAM 

Assist solution for Autodesk Fusion and Mastercam today. 

further information: www.cloudnc.com 


components 

Precise, highly reliable linear technology solutions 

for machine tools 

At AMB 2024 Rollon presented a wide range of 

products and solutions for machine tools. The company’s 

focus at the trade show was on high-performance 

ball screws of the Shuton-Ipiranga brand, as well as 

roller guides from Rosa Sistemi. The full-range supplier 

exhibited also linear guide rails, telescopic slides and 

actuators. 

Rollon is among the world’s leading suppliers of linear motion 

solutions and offers unique development, production, 

system, and application expertise from a single source. 

Whether for machine tables, tool heads, automatic machine 

doors, loading and unloading systems, pull-out drawers, door 

openings, movable control elements or traversing axes for 

robots and cobots: the diverse products are designed for numerous 

machine tool applications, where they ensure a high 

level of efficiency and process reliability in metal working. 

Visitors to the Rollon-Shuton-Ipiranga booth at AMB 

could explore the extensive product range and discover the 

advantages for their particular application. The focus was on 

high-performance ball screws from Shuton-Ipiranga as well 

as profile rails from Rosa Sistemi. 

Precision ball screws from Shuton-Ipiranga 

Shuton-Ipiranga, known for their high-precision ball screws, 

is a key player in machine tool construction. The XP Xtrem 

Position product family was developed with special emphasis 

on linear motions in machine tools and features exceptional 

rigidity, dynamics and positioning accuracy. Available in 

two versions – COMPLEX and PRIME – the products ensure 

a long service life and absolute reliability. The COMPLEX 

series – designed for high speeds and heavy loads – is used for 

example in five-axis machining centers, multi-spindle machines 

and mold processing machines. The PRIME series includes 

high-precision ball screws with a small pitch for medium-speed 

applications, such as grinders or EDM machines. 

For applications requiring heavy-duty actuators, such as injection 

molding, the energy sector, lifting systems, and presses, 

the XL Xtrem Load product family is the best choice. The 

ball screws have been optimized for heavy-duty applications 

to guarantee maximum load-bearing capacity, dynamics, 

and efficiency. Three type – IML, HDL and PKL – are available 

for achieving an optimal service life under different load 

ratings and speed requirements. 

Roller guides from Rosa Sistemi 

Within the Rollon Group, Rosa Sistemi specializes in profile 

rails, such as the MG Rail as the perfect answer to the increasing 

technological challenges of the machine tool sector. 

The COMPLEX series is designed for high speeds 

and heavy loads 

The roller guide features hardened and ground running surfaces 

with rollers to meet the typically stringent requirements 

for precision, dynamics and efficiency with no compromises. 

Thanks to their high load bearing capacity, outstanding 

rigidity, an innovative lubrication and seal concept, as well as 

high reliability even in dirty environments, the MG Rail is 

the ideal solution for high-precision positioning. 

Broad application spectrum 

Rollon also offers other technologies for the fast and precise 

handling of parts and tools. Machine doors and vertically 

opening doors benefit from the self-aligning linear guide 

rails of the Rollon Compact Rail and X-Rail series. Their 

self-aligning capability allows fast and easy compensation of 

inaccuracies in the mounting surfaces. The telescopic slides 

of the Telescopic Rail series exhibit only minimal deflection 

even when fully extended under maximum loads, which 

makes them ideal for pull-out elements such as drawers and 

control panels. To increase the efficiency of robots and cobots, 

the work area can be expanded significantly with a Robot 

Transfer Unit (RTU). 

Linear technology for machine tools 

No matter what type of machine tool application: based on an 

extensive product range and a high level of system solution 

competence, Rollon offers suitable components and systems – 

from ball screws to roller guides and linear technology, from 

a single source. All the solutions have been developed for 

maximum performance and reliability to ensure high productivity, 

optimal product quality and trouble-free operation – 

whether the requirement is for a standard product or a 

custom development. 

further information: www.rollon.de 


49

components 

Röhm HP Pro live center in 

precision version 

Precise 

With its new Pro 

lines HP Pro and 

HVLP Pro, the clamping 

and gripping specialist 

offers its live 

centers in precision 

design. With a concentricity 

of 0.003 mm, the new HP Pro and HVLP Pro live 

centers from Röhm set standards when it comes to the 

precise counter-clamping of workpieces on lathes and 

grinding machines. 

The live centers of the HVLP Pro series are equipped with an 

extended center point. This enables better tool accessibility 

thanks to a smaller interfering contour and therefore more 

space between the center point and the workpiece. Each of 

these live centers is carefully checked for concentricity on the 

test bench after assembly. 

“Our live centers with the blue ring have always been the 

benchmark for precision and durability in efficient workpiece 

machining. I am therefore pleased that we can take this 

precision to the extreme, so to speak, with the Pro lines”, says 

Gerhard Glanz, CEO of Röhm GmbH. 

High stability and accuracy 

Like all Röhm live centers, the Pro line centers have also triple 

bearings, being specially developed to absorb high axial 

and radial forces. This feature makes them the ideal choice 

for particularly demanding machining operations where the 

focus is on stability and reliability. Thanks to the lifetime 

lubrication, Röhm live centers are maintenance-free. 

“Many lathe operators and machining specialists know this: 

Röhm live centers are not only highly precise, but also very 

durable. It’s great that we can now offer precision centers 

with the Pro versions”, says Gerhard Glanz. 

The HP Pro with classic Röhm live center (angle 60 °) is 

available in MK 2 (size 102) to MK 6 (size 114); the HVLP Pro 

variant with extended center point is available in MK 3 (size 

106) to MK 6 (size 114). 

further information: www.roehm.biz 

Fast on the move 

can be customized and further developed”, explains 

Werner Mäurer, managing director of HIWIN GmbH. “This 

allows us to significantly reduce the development times of 

such complex precision systems for our customers. With our 

fast response time, the customer then has its precision system 

in use within a very short time.” 

Thanks to standardized types, development times for complex 

motion and positioning systems can be significantly reduced 

Preconfigured motion systems save a lot of development 

time. By providing standard designs, HIWIN 

enables faster and more targeted integration of sophisticated 

motion and positioning solutions into the 

customers own machine concepts. 

Thanks to their modular design HIWIN’s precision axes 

and precision systems can be customized to the costomers 

own requirements without any major design effort. “Our 

standardized axes and systems are like a sample kit that 

From components to ready-to-install systems: with mechanical 

and electromechanical components as the foundation 

of every movement, today HIWIN is also a drive technology 

specialist. The motion systems for automation, sorting and 

placement, inspection or exposure are used in the automotive 

industry, medical and measurement technology or the semiconductor 

industry. “Our customers can choose between a 

pure component solution, a customized motion subsystem 

or a fully integrated motion and positioning solution. We 

supply everything from a single source.” 

For the configuration of the standardized movement and 

positioning systems, HIWIN provides project planning 

sheets that allow the available types to be easily adapted to 

the customers requirements. CAD data for the standardized 

versions is available for direct download. 

further information: www.hiwin.tw 


impressum 

ISSN 2628-5444 

publisher 

Benno Keller 

phone + 49 (0)911 - 2018 200 

fax + 49 (0)911 - 2018 100 

keller@harnisch.com 


Eric Schäfer 

phone +49 (0)911 - 504 98 82 

fax +49 (0)911 - 506 38 32 

eric.schaefer@harnisch.com 

managing editor 

Christiane Ebner 

phone +49 (0)911 - 2018 260 

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ebner@harnisch.com 

publishing company 

Dr. Harnisch Publications 

management board 

Dr. Claus-Jörg Harnisch 

Benno Keller 

Eschenstrasse 25 

90441 Nuremberg 

Germany 

phone +49 (0)911 - 2018 0 

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hpt@harnisch.com 

www.harnisch.com 

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advertising Germany, Austria, Switzerland 

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Four issues per year 

printed by 

Schleunungdruck GmbH 

Eltertstrasse 27 

97828 Marktheidenfeld, Germany 

VAT DE 133 510 873 

Boehlerit GmbH & Co. KG ............16 

CERATIZIT ........................10 

CloudNC .......................... 48 

Coborn Engineering Co Ltd ...........37 

DN Solutions. . . . . . . . . . . . . . . . . . . . . . . 44 

EMAG GmbH. ......................45 

EMCO GmbH. ..................... 42 

Fritz Studer AG .................... 38 

GEFERTEC GmbH ..................41 

GF Machining Solutions 

Management SA ...................43 

Gühring KG ........................15 

Guill Tool & Engineering Co., Inc. .....25 

Hardinge Kellenberger AG. . ..........28 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH .............. 12, 13 

HIWIN GmbH ......................50 

HUFSCHMIED 

Zerspanungssysteme GmbH.. . .......34 

igus GmbH .........................47 

KAPP GmbH & Co. KG. . .............26 

Lach Diamant Jakob Lach 

GmbH & Co. KG ............... 16, 22 

company finder 

Liebherr-Verzahntechnik GmbH . .... 40 

MAG IAS GmbH (FFG). . ............ 20 

MAPAL Fabrik für Präzisionswerkzeuge 

Dr. Kress KG ......................21 

Mikron AG, Division Tool ............18 

MMC HARTMETALL GmbH .........17 

ModuleWorks GmbH ................25 

Platinum Tooling Technologies, Inc ....19 

Reishauer AG ........................6 

Roeders GmbH. . ....................34 

Röhm GmbH. . ......................50 

Rollon GmbH. . .....................49 

Saint-Gobain Abrasives GmbH. . ......30 

SCHUNK SE & Co. KG ..............21 

SIMTEK Präzisionswerkzeuge GmbH ..14 

TIGRA GMBH ..................... 20 

TSUBAKI KABELSCHLEPP GmbH .. 46 

UNITED GRINDING Group ........ 44 

WEILER Abrasives GmbH. ............9 

ZCC Cutting Tools Europe GmbH. ....11 

The articles contained in this magazine, 

including the illustrations, are subject 

to copyright law. Any use without the 

consent of the publisher is not permitted 

and will be prosecuted. This applies to 

every conceivable form of reproduction. 

Copies and reprints can be ordered on 

request. Articles which are identified by 

name or which are to be assigned to an 

author by an abbreviation do not necessarily 

reflect the opinion of the editorial staff. 

Unsolicited manuscripts cannot be returned. 

If a manuscript is accepted by the editorial 

staff, publishing and copyright law as well 

as all rights for publication and distribution 

are transferred to the publisher. The 

publisher accepts no liability with regard 

to the facts set out in these articles. 

copyright © 2024 Dr. Harnisch Publications 

advertising index 

Jimmore International Corp. .............................................page 3 

Kapp GmbH & Co. KG ..................................................page 11 

Lach Diamant Jakob Lach GmbH & Co. KG ............................. back cover 

Mikron AG, Division Tool ...............................................page 9 

Reishauer AG ............................................................cover 

SPR ABRASIVES. ......................................................page 13 


51

... a must have for turning aluminium 

® 

®

hp tooling 2024-#4

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